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TSB 05-15-5 IRS Axle Shaft Seal Leak

Discussion in '!! List of Ford Explorer & Ranger "How To Repair" ' started by ExplorerDMB, September 30, 2006.

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    1. ExplorerDMB

      ExplorerDMB Moderator/Technician Moderator Emeritus

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      Year, Model & Trim Level:
      2004 Acura TL
      TSB
      05-15-5 LEAKS FROM REAR HALFSHAFT AXLE SEAL

      Publication Date: July 13, 2005

      FORD: 2002-2005 Explorer
      2003-2005 Expedition
      LINCOLN: 2003-2005 Aviator, Navigator
      MERCURY: 2002-2005 Mountaineer


      This article supersedes TSB 04-10-5 to update the vehicle lines, model years, Service Tips and labor operations.

      ISSUE:
      Some Expedition/Navigator vehicles built before 2/16/2005 and Explorer/Mountaineer, Aviator vehicles built before 3/18/2005, all equipped with the 8.8" or 9.75" ring gear and independent rear suspension (IRS), may exhibit leaks at the rear halfshaft axle seals. A new unitized seal is now available for service. The new seal design eliminates the need to use seal protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is required.

      ACTION:
      Order and install the new seal to correct leak condition. Review the Instruction Sheet included in the kit and obtain the required tools before beginning repair. Refer also to the following installation Service Tips.

      INSTALLATION SERVICE TIPS

      Refer to Workshop Manual Section 205-05 for half shaft removal and installation.

      Use only the proper seal installation tool, Rotunda tool (206-034).
      Ensure the seal installation tool is clean and free of debris prior to inserting into new seal. Do not use a damaged seal installation tool exhibiting nicks, burrs, or sharp edges.
      NOTE: THE USE OF SEAL PROTECTOR 1L2W-4N206-AA IS NO LONGER REQUIRED.



      Do not tap directly on the back of the seal installation tool, always tap on the handle, per Instruction Sheet. Seal should be driven evenly into housing bore with only enough force to seat in the bore.
      Before installing the halfshaft, verify that the inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is present, follow the kit Instruction Sheet and remove the excluder seal.
      NOTE: OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. LUBRICANT SPECIFICATIONS CAN BE FOUND IN THE WORKSHOP MANUAL.




      PART NUMBER PART NAME
      5L1Z-4A109-A Axle Seal Kit


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

      OPERATION DESCRIPTION TIME
      051505A 2002-2005 Explorer/Mountaineer 2003-2005 Aviator Replace One Rear Axle Seal (Do Not Use With 4139A, 4139AT, 4139A2, 4139A2T) 0.9 Hr.
      051505A 2003-2005 Expedition/Navigator Replace One Rear Axle Seals (Do Not Use With 4139A, 4139AT, 4139A2, 4139A2T) 0.9 Hr.
      051505B 2002-2005 Explorer/Mountaineer 2003-2005 Aviator Replace Both Rear Axle Seal (Do Not Use With 4139A, 4139AT, 4139A2, 4139A2T ) 1.7 Hrs.
      051505B 2003-2005 Expedition/Navigator Replace Both Rear Axle Seals (Do Not Use With 4139A, 4139AT, 4139A2, 4139A2T ) 1.5 Hrs.

      DEALER CODING
      BASIC PART NO. CONDITION CODE
      4A109 42


      Information is gathered via gijoecam and Napafix.com
       
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    3. Pontisteve

      Pontisteve Active Member

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      This was superceded by TSB 06-22-5.

      http://ford.justanswer.com/uploads/kennyz1963/2008-07-16_200342_tsb06-22-05.pdf

      Basically, the old axle seal was a 2 piece design. One piece sat on the inner cv joint housing (where it contacts the axle seal), and the other piece was the axle seal itself. The newest axle seal kit 7L1Z-4A109-D (02-07 explorers) is a one-piece seal and a new circlip (axle retaining clip). The update instructions say to do away with the seal that is pressed onto the cv joint housing, and just use the new 1-piece seal. It calls for some special tools, which amount to a 2.5 lb slide hammer attached to a bearing/seal puller, which is just a 3-jaw internal puller legs. You can pull the bearing and seal, or just the seal itself.

      You are also supposed to use the new Lisle 17850 seal installer. It's basically a Ford seal driver with a really long hammer, that allows you to hammer it in from about 2 feet away, so you can clear the frame tube and all. It says not to tap on the seal or the seal driver itself, but to tap on the driver handle, to ensure an even seal installation. Then, you're supposed to check the gap between the seal flange and the rear end housing, to make sure that there is no more than a .010" gap all the way around. I guess in other words, make sure you tap it all the way in.

      I bought an OTC slide hammer kit and a slide hammer extension and a cv fork (all OTC), to use instead of Ford's cv fork and driver/handle. Basically, Ford calls for pushing/hammering the cv joint out, while I'm trying to pull/slide hammer it out instead. If my slide hammer doesn't produce enough weight/action, then I may have to hammer it out from the other direction instead. Hope this helps someone.
       

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