Drivetrain - 4X4 Front Axle Noise in 2 High Only
Article No.03-6-4
03/31/03
^ NOISE - 4X4 - FRONT AXLE NOISE IN 2 HIGH ONLY
^ AXLE - 4X4 - FRONT AXLE NOISE IN 2 HIGH ONLY
FORD:
2003 EXPEDITION
LINCOLN:
2003 NAVIGATOR
Article 02-25-7 is being republished in its entirety to clarify specific tool usage.
ISSUE
Some 2003 Expedition/Navigator 4X4 vehicles may exhibit a front axle groan or hum, and/or a slight vibration, when operated in the 2 High mode. This condition is most noticeable on deceleration between 45 and 15 mph, and is not present in A4WD or 4 High. This may be due to the front halfshafts rotating at different speeds when the vehicle is operated in 2 High.
ACTION
To service, install S-spring (clutch spring) into the front axle differential, causing the front halfshafts to rotate at the same speed in 2 High mode. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
WARNING
THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE LEFT REAR QUARTER TRIM PANEL. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
1. Position the vehicle on a hoist.
2. Remove the differential housing cover (3N136). Remove the bolts, differential housing cover and allow axle lube to drain.
3. Locate and remove the differential Pinion Shaft Retaining Bolt (D8BZ-4241-B) as shown in Figures 1 and 2.
4. Remove the differential pinon shaft.
NOTE
IT IS ONLY NECESSARY TO PARTIALLY REMOVE THE PINION SHAFT ENOUGH TO CLEAR THE SPACE BETWEEN THE PINION GEARS FOR S-SPRING INSERTION. IF YOU COMPLETELY REMOVE THE DIFFERENTIAL PINION SHAFT, BE CAREFUL NOT TO ALLOW THE PINION GEARS TO BECOME MISALIGNED.
5. Remove both axle shaft snap rings, as shown in Figure 3.
NOTE
PROCEDURE WORKS BEST WITH A HIGH-QUALITY SNAP-RING PLIERS, SUCH AS SNAP-ON P/N PR 229A FIXED TIP 90 DEGREE.
6. Clear and hold axle shafts beyond the face of the side gears.
NOTE
THE AXLE SHAFT SHOULD ONLY BE PULLED OUT FAR ENOUGH TO ALLOW INTRODUCTION OF THE S-SPRING. DO NOT PULL THE AXLE SHAFT PAST THE SIDE GEAR. ENSURE THAT THE AXLE SHAFT IS CONSTANTLY SUPPORTED IN TWO LOCATIONS, AT BOTH THE SHAFT BEARING AND THE SIDE GEAR. THIS WILL PREVENT THE AXLE SHAFT FROM DROPPING DOWN AT AN ANGLE AND DAMAGING THE OIL SEAL.
7. Place a Differential Clutch Spring (EOAZ-4214-A) between the side gears of both RH and LH axle shafts, as shown in Figure 4. To install the differential clutch spring use a soft-faced hammer or hardwood block. Tap into position and center between side gears (Figure 4).
8. Install new Axle Shaft Snap Rings N808765-S on RH and LH sides. Do not reuse the old snap rings. Push in on the axle shafts and install new snap rings.
NOTE
PROCEDURE WORKS BEST WITH A HIGH-QUALITY SNAP-RING PLIERS, SUCH AS SNAP-ON PIN PR 229A FIXED TIP 90 DEGREE.
9. Reinstall the differential pinion shaft and install a new Pinion Shaft Retaining Bolt, Part Number D8BZ-4241-B.
10. Remove all traces of old silicone prior to reinstalling front differential housing cover, and clean metal mating surfaces with Metal Surface Cleaner, F4AZ-19A536-RA or equivalent meeting WSE-M5B392-A. Install the front differential cover using Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting WSE-M4G323-A4. Following procedure in Section 205-03 of Workshop Manual, torque bolts to 24 Lb-ft (32 N.m).
NOTE
FRONT DIFFERENTIAL HOUSING COVER MUST BE INSTALLED WITHIN 15 MINUTES OF APPLYING SILICONE, OR SURFACES MUST BE RECLEANED AND SILICONE REAPPLIED. ALLOW SILICONE TO CURE ONE HOUR BEFORE FILLING.
11. Fill axle with 3.6 pints Motorcraft SAE 75W-90 Fuel Efficient High Performance Rear Axle Lubricant XY-75W90-QFEHP. Lubricant level should be 0.38 in (9.56 mm) below bottom of differential housing fill hole.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-25-7
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
030604A Install S-Spring (Clutch 1.7 Hrs.
Spring) Into The Front Axle
Differential
DEALER CODING
CONDITION
BASIC PART NO. CODE
3K147 42
OASIS CODES: 509000, 597997, 701000, 702000, 703000, 703200, 703300
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