Change the fluid now stuck in 4x4 all the time

[elester12]

Hello all,

I just changed all my fluids in the explorer (transfer/trans/diffs) --- The car drove fine after for about 10 miles. The next morning when I was reversing my tires were in a way dragging. It seems like my car's 4x4 is on all the time now. Any ideas?!

Thanks!

 

[IZwack]

What type of fluid did you put in the transfer case?

 

[elester12]

mobil 1 Syn ATF. it said its compatable with Mecon...

 

[IZwack]

That should be fine. Try electrically isolating the transfer case from the rest of the vehicle -- disconnect all of its electrical connectors (there are two connectors on the 2nd generation Explorer, I'm not sure how many there are on teh 3rd generation).

If the vehicle still remains in 4wd, then you know its a mechanical problem with the transfer case.
If the vehicle comes out of 4wd, then its an electrical problem.

If the vehicle still remains in 4wd, I would next park the vehicle uphill and drain the transfer case (parked uphill to ensure you get as much fluid out). I would look at the status of the fluid (burnt?) and look for any foreigh metals in the fluid. Then just to be sure, I would refill with regular Mercon/Dexron-III fluid -- its cheap enough per quart . 3 quarts of this fluid should cost you around $10 (most transfer cases take less than 3 quarts).

 

[elester12]

well I ended up taking it to the dealer... They said the rear clutches in the diff were bad. They replaced them with some kit. I noticed they put an additive into the diff oil but I dont have limited slip...atleast I dont think I do...

but that did solve the problem!!! Amazing how i would only feel it when I was turning the car... it felt as if it was coming from the front, not the back!

 

[rrgone]

well I ended up taking it to the dealer... They said the rear clutches in the diff were bad. They replaced them with some kit. I noticed they put an additive into the diff oil but I dont have limited slip...atleast I dont think I do...

but that did solve the problem!!! Amazing how i would only feel it when I was turning the car... it felt as if it was coming from the front, not the back!

Were you hearing the notorious whine from the rear end before you changed out the fluids? How many miles on your '02? Glad you got it fixed and thanks for posting your solution!

 

[elester12]

I was not having any noise problem at all until the repair was made!!!!!!! I have 81,000 miles on my SUV. I was planning on making a trip back to the dealer... I can hear this noise when I am giving it gas going about 50-60mph --- when i let go of the gas it goes away. There was no noise issue before I changed the fluid-- i only did it because I did not know when it was last done by the previous owner.

 

[IZwack]

Curious : what type of gear oil did you put in the rear differential (synthetic or non-synth)?

If it was non-synth, did you put a bottle of "Friction Modifier" additive?

 

[elester12]

I used the ford 75-140 and no i did not add that additive... I wonder if thats what made my clutches go bad?

now, ford did use the 75-140 and added that friction additive...

 

[elester12]

Heres a question- how do you know if you have limited slip diff's?

 

[IZwack]

I wonder if thats what made my clutches go bad?

That could very well be the cause -- the additive is supposed to control friction buildup between the "unlock" and "lock" transition -- technically refered to as "dynamic" and "static" phases.

Without the additive, some people describe it as driving with a spool or welded-up spider gears -- which sounds like your situation.

TRS article on the Limited Slip differential and the purpose of the additive:
http://www.therangerstation.com/tech_library/rebuild_tractionlock.htm

Heres a question- how do you know if you have limited slip diff's?

I think the forum says to look at the "AXLE" code on the sticker on driver's door, if you find a "D" in it, then you have a Limited Slip Differential. But having said that, I once went to the junk yard looking for a non-Limited Slip differential and found an Explorer w/o the D code, but when I popped off the diff cover, I saw clutch packs -- perhaps the owner swapped axles or differentials

http://www.explorerforum.com/forums/showpost.php?p=1622699&postcount=2

 

[IZwack]

Quick question, do you remember if the 75-140 you used was synthetic?

I ask because all synthetics are "supposed" to come with the friction modifier already in the fluid.

 

[elester12]

the 75-140 i used (ford brand) was full synthetic. The bottle did say if you have LSD then you need to put the additive in there... I had no idea it had limited slip! What I dont understand is why did they replace the clutches inside--- shouldnt they have just added the additive?

 

[elester12]

Hey guys here's a question... after they did my LSD clutch replacement... I hear this noise at 50-55mph when I have my foot on the gas. The noise comes from the rear and will go away as soon as i release the gas- You only hear it at 50-55mph on the highway. Any ideas?

 

[IZwack]

What I dont understand is why did they replace the clutches inside--- shouldnt they have just added the additive?

I mean to respond to this but I forgot, anyway, how long did they have the vehicle? Because replacing those clutch packs is not a quick job.

Hey guys here's a question... after they did my LSD clutch replacement... I hear this noise at 50-55mph when I have my foot on the gas. The noise comes from the rear and will go away as soon as i release the gas- You only hear it at 50-55mph on the highway. Any ideas?

Maybe the pinion bearing ..

 

[elester12]

the ticket says it took 6.5 hours and they had my car for one day. i'm thinking about taking it back to him and also complaining about the 2-3 shift issue... may as well push that used car warranty

 

[rrgone]

Tsb 05-23-3

Looks like your shop didn't follow the note at the end of the TSB. But it does seem that he didn't charge the full 6.6 hrs of shop time he could have for a 2002-2005 Explorer though.

TSB
05-23-3 REAR AXLE NOISE REPAIR

Publication Date: November 4, 2005

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 YL3Z-4662-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-S439 - Wheel End Nuts
390266-S100 - 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, 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) 4.7 Hrs.
052303A 2003-2005 Expedition: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4) 5.8 Hrs.
052303A 2003-2005 Expedition/Navigator With Air Suspension: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4) 5.9 Hrs.
052303A 2002-2005 Explorer/Mountaineer, 2003-2005 Aviator: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4) 6.6 Hrs.

DEALER CODING
BASIC PART NO. CONDITION CODE
4209 14

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NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2005 Ford Motor Company