2003 Ford Expedition Rear-end

Unfortunately, this is a somewhat common problem. Ford has issued several Techinical Service Bulletins related to rear end noise. Unless you have an extended warranty, this is something you will ahve to pay to change.

TSB 05-23-3 11/28/05

REAR AXLE NOISE REPAIR\

FORD:

1997-2005 Expedition, F-150 2002-2005 Explorer LINCOLN: 1998-2005 Navigator 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer

This article supersedes TSB 05-12-6 to update the Service Kit and Service Procedure information.

ISSUE

Some vehicles may exhibit an axle whine or hum during acceleration, deceleration and/or cruise.

ACTION An axle repair kit has been developed which incorporates most parts required for a comprehensive axle repair. The kit should be used instead of installing a complete axle assembly to repair an axle whine/hum. Replace Ring and Pinion with Axle Kit and Components.

NOTE REFER TO THE "DIFFERENTIAL RING AND PINION" IN-VEHICLE REPAIR PROCEDURE IN THE ONLINE WORKSHOP MANUAL SECTION 205-00, FOR THE LATEST AXLE DIAGNOSIS AND REPAIR PROCEDURES.

NOTE FOR 1999 AND PRIOR MODEL YEAR VEHICLES, USE THE 2000 MODEL YEAR WORKSHOP MANUAL.

NOTE WHEN SERVICING THE REAR AXLE ON ANY 2002-2004 F-150, EXPEDITION, NAVIGATOR, EXPLORER OR MOUNTAINEER BUILT BEFORE 3/30/2004, IF FLUID REPLACEMENT IS REQUIRED, REPLACE THE ORIGINAL FUEL EFFICIENT HIGH PERFORMANCE (FEHP) SAE 75W-90 REAR AXLE LUBRICANT WITH SAE 75W-140 HIGH PERFORMANCE SYNTHETIC REAR AXLE LUBRICANT. WHEN THE FLUID TYPE IS CHANGED, REPLACE THE CURRENT "FEHP" METAL TAG WITH A NEW "75W-140" TAG (F3TZ-4121-AA). IN ADDITION, REMOVE OR BLOCK-OUT THE FEHP REFERENCE ON THE MULTI-COLORED LABEL LOCATED ON THE RIGHT SIDE AXLE TUBE. IF THE AXLE IS A LIMITED-SLIP MODEL, USE XL3 ADDITIVE FRICTION MODIFIER IN THE QUANTITY RECOMMENDED BY THE WORKSHOP MANUAL.

KIT ORDERING: REFER TO THE VEHICLE AXLE TAG FOR AXLE RATIO IDENTIFICATION

- 5L3Z-4209-A = (8.8-Inch Ring Gear/3.31 ratio) (1997-2005 F-150)

- 5L3Z-4209-B = (8.8-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 2002-2005 Explorer/Mountaineer/Aviator)

- 5L3Z-4209-C = (8.8-Inch Ring Gear/3.73 ratio) (1997-2005 F-150, 2002-2005 Explorer/Mountaineer/Aviator, 2003-2004 Expedition/Navigator)

- 5L3Z-4209-D = (9.75-Inch Ring Gear/3.31 ratio) (1997-2005 F-150, 2005 Expedition/Navigator, 1997-2002 Expedition/Navigator)

- 5L3Z-4209-E = (9.75-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 1997-2002 Expedition/Navigator)

- 5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) (1997-2005 F-150, 1997-2005 Expedition/Navigator)

NOTE 9.75 REAR AXLE HOUSINGS WERE REDESIGNED IN MID-1999, INCREASING FRONT PINION BEARING SIZE. REPLACING RING & PINIONS IN AN OLD-STYLE AXLE ASSEMBLY WILL REQUIRE INSTALLATION OF SPACER P/N YL3Z4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND COLLAPSIBLE SPACER.

THE AXLE SERVICE KITS INCLUDE THE FOLLOWING COMPONENTS:

- 4630 - Head Bearing

- 4628 - Head Bearing Cup

- 4676 - Pinion Seal

- 386989-S2 - Washer (Slinger)

- 4621 - Tail Bearing

- 4616 - Tail Bearing Cup

- 4222 - Differential Bearing Cups

- 4221 - Differential Bearings

- 4209 - Gear Set (includes pinion shims, pinion nut and crush spacer)

- 4209 - Instruction Sheet

NOTE THE KIT DOES NOT INCLUDE THE FOLLOWING ITEMS. SOME OR ALL OF THESE ITEMS WILL BE REQUIRED TO COMPLETE THE AXLE SERVICE, DEPENDING ON AXLE APPLICATION/STYLE.

ORDER AS NEEDED:

NOTE REUSE OF RING GEAR BOLTS, CARRIER BEARING CAP BOLTS AND DIFFERENTIAL SLAVE PIN RETAINING BOLT REQUIRES CLEANING OF THREADS AND INSTALLATION OF TA-27 STUD AND BEARING MOUNT RETAINING COMPOUND & SEALANT.

- YL3Z-4662-CA - Pinion Bearing Spacer for 1997-1998 9.75 axles

- XG-14 - Gear Marking Compound

- 4067 - Differential Shims 0.241" to 0.307"

- SAE XY-75W140-QL - High Performance Synthetic Rear Axle Lubricant

- XL-3 - Additive Friction Modifier (Limited Slip Axles Only)

- 205-506 - Seal Protectors (Rotunda Tool)

- W710084-5439 - Wheel End Nuts

- 390266-S199 - Differential Slave Pin Bolt (9.75" axles)

- 387426-S100 - Differential Slave Pin Bolt (8.8" axles)

- 4B422 - Axle Circlips

- ZC-21 - Metal Surface Cleaner

- TA-29 - Ultra Silicone Sealant

- TA-27 - Stud and Bearing Mount Retaining Compound and Sealer

- F3TZ-4121-AA - Fluid Tag (REQUIRED IF FLUID TYPE IS CHANGED FROM FEHP DURING REPAIR)

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME

052303A 1997-2002 Expedition, 4.7 Hrs. 1998-2002 Navigator, 1997-2004 F-150 Heritage, 2004-2005 F-150: Rear axle Noise Repair (Includes Time For Road Test To Verify Concern (Beam Axle)) (Do Not Use With 4205A Or 4205A4)

052303A 2003-2005 Expedition: 5.8 Hrs. Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

052303A 2003-2005 5.9 Hrs. Expedition/Navigator With Air Suspension: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

052303A 2002-2005 6.6 Hrs. Explorer/Mountaineer, 2003-2005 Aviator: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (lrs Axle)) (Do Not Use With 4010D Or 4010D4)

DEALER CODINGCONDITION BASIC PART NO.CODE 420914

OASIS CODES: 509000, 590000, 597997, 702000, 702200, 703200, 703300, 703400,

790000

This is good info, I have been searching for repair information on my 2001 Expedition. My situation is I am deployed to OIF, my family is in Germany. My wife is having problems with rear end noise, it got so bad she doesn't want to drive it. The local "Ford" garage comfirmed rear end problem, but would not pull the back cover off to verify what it is exactly. They say they don't have the expertise or tools to do internal repairs on the differential and that if my wife could find an axle they would replace it. Sure, I asked my wife why she didn't go to the local store and just pick one up. I wrote Ford explaining my problem only to be referred back to that same garage, so it looks like I am on my own with this one. Anyway, I have to wait until I go on R&R to repair the vehicle and it sounds like this kit would cover just about anything that might be wrong. Only the diff ID# my wife gave me ID# V821M L331 881F21 does not match the kits you mentioned. Also does anyone know where I could order this kit that would ship overseas to germany. Thanks for your support!

And after reading the complete TSB i'm wrong............

OllieB wrote:

I missed the beginning of the thread. Where can I find the TSB. I have a

2003 Expedition. I wanted to change the rear-end oil, but the manual doesn't mention any maintenance.

Darrell