Attachment III - Technical Information
OVERVIEWThe rear axle housing assembly will be replaced in the affected vehicles. The original rear axle assembly used for this recall is no longer in production. There were significant changes to the rear axle assembly for the 2003 model year, making the rear axle assembly non-transferable to the 2002 FX4 Ranger. The new assembly will not be equipped with brake assemblies, axle shafts, differential thrust plate and lock bolt, axle vent assembly or wheel bearings and oil seals. Other than installing new rearwheel bearings and oil seals, these items must be transferred from the original axle. Remove and discard the unpainted cover from the new rear axle housing and clean and transfer the painted cover from the original rear axle.
This service procedure refers the technician to the workshop manual for rear axle housing replacement.
Included are some highlights of the repair.
Be sure to read this Attachment III completely before proceeding to the workshop manual.
SERVICE PROCEDURE
Replace the rear axle housing assembly as outlined in Section 205-02C: Rear Axle/Differential - Ford 8.8-Inch Ring Gear High Torque of the 2002 Ranger Workshop Manual.
Components Transferred to the New Rear Axle Housing Assembly
^ Differential thrust plate and lock bolt
^ Axle shafts and U-washers
^ Differential housing cover
^ Axle vent assembly
^ Brake assemblies
Service Notes
^ Prepare the axle housing tubes for painting by removing all dirt, debris and oil. Following proper painting procedures, paint the tubes with Ford Low Temperature Anti-Corrosion Coating PM-12-A (or equivalent meeting Ford specification ESB-M2P30-B). Avoid getting any paint on the wheel bearing or oil seal surfaces. Note: It is recommended to paint the axle assembly prior to beginning the axle replacement procedure. It may take approximately one (1) hour for the paint to dry.
^ No backlash or preload checks are required.
^ DO NOT disconnect brake hydraulic lines.
^ Align the painted index mark on the driveshaft with the dot on the pinion flange when installing the driveshaft.
^ After installing the brake backing plates, install new rear wheel bearings and oil seals as outlined in the workshop manual.
Torque Specifications
^ Rear spring U-bolt nuts tightened in cross pattern - 103 Nm (76 lb-ft)
^ Shock absorbers - 68 Nm (50 lb-ft)
^ Driveshaft bolts in cross pattern - 112 Nm (83 lb-ft)
^ Brake backing plate nuts - 62 Nm (45 lb-ft)
^ Differential thrust plate lock bolt - 30 Nm (22 lb-ft)
^ Differential housing cover - 45 Nm (33 lb-ft)
^ Wheel lug nuts - 135 Nm (100 lb-ft)
Fluid and Sealer Requirements
^ Thread lock and Sealer-EOAZ-19554-AA (or equivalent meeting Ford specification WSK-M2G351-AS [type II])
Applications - a) Differential thrust plate lock bolt
b) Driveshaft bolts
^ Synthetic Rear Axle Lubricant - XY-75W-140-QL (or equivalent meeting Ford specification WSL-M2C192-A)
^ Quantity-2.54 liters (5.37 pints)
^ Friction Modifier-XL-3 (or equivalent meeting Ford specification EST-M2C1189-A) Quantity-one (1) 4-ounce bottle
^ Silicone Rubber - F7TZ-19554-AA (or equivalent meeting Ford specification WSS-M4G320-A3)
^ Premium Long Life Grease-XG-1-C (or equivalent meeting Ford specification ESA-M1C75-B)
^ Low Temperature Anti-Corrosion Coating PM-12-A (or equivalent meeting Ford specification ESB-M2P30-B)