Drivetrain - Front Drive Axle Vent Tube Fluid Leaks
TSB 05-6-2004/04/05
FRONT AXLE LEAKS FLUID FROM VENT TUBE -
VEHICLES EQUIPPED WITH 4X4 OR AWD
FORD:
1995-2001 Explorer
1997-2005 Ranger
2001-2003 Explorer Sport
2001-2005 Explorer Sport Trac
MERCURY:
1997-2001 Mountaineer
This article supersedes TSB 03-05-08 to update the model year applications and to revise the Service Procedure.
ISSUE
Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles, may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown toward the axle vent by the gears during vehicle operation.
ACTION
Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE PROCEDURE.
1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the lower engine splash shield, if equipped.
3. Index-mark the front axle pinion flange and the front driveshaft.
4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts.
5. Tape the U-joint bearing caps to prevent them from falling off the U-joint.
6. Swing the driveshaft away from the axle pinion yoke and secure out of the way.
7. Remove the three (3) axle support mounting bracket bolts from the axle housing.
8. Position suitable jack beneath axle housing.
NOTE
PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE.
9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts.
10. Carefully lower and position the axle housing until it is resting on the torsion bars.
11. Disconnect the vent hose from the axle housing.
12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow easy access to the axle cover bolts. Remove the axle housing cover and discard.
13. Clean the axle housing cover mounting surface.
14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing surface.
15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m).
16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the kit (Figure 1).
17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit.
18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque the bolts to 49 lb-ft (66 N.m).
19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106 N.m).
20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m).
21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90 Premium Rear Axle Lubricant. Install fill plug.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050620A 1995-2001 Explorer 1.5 Hrs.
1997-2001 Mountaineer
1997-2005 Ranger
2001-2003 Explorer Sport
2001-2005 Explorer Sport
Trac: Install A Revised
Axle Cover Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
4022 D1
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