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Old 12-17-2005, 18:16   #1 (permalink)
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2003 Ford Expedition Rear End Noise

I have a 2003 Expedition EB 4x2 that has a whining noise at road speeds which seems to be coming from the rear end. It does not seem to occur when the vehicle is coasting. It reminds me of an old Beamer I had when the rear end was going out! Since I have 44k miles I assume it's not covered under warranty. I just bought the SUV used afew months ago. Any ideas?

Thanks
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Old 12-23-2005, 08:08   #2 (permalink)
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Re: 2003 Ford Expedition Rear End Noise

There is a TSP for this which tels them to put a rebuild kit including geas, bearingsand seals in the rear.

It is onlt available under warranty though. Maybe your dealer we help you out.

When my 2004 did it they reaplaced the whole differential, now they just do certain parts.

See Below----Bob


TSB

Drivetrain - Drive Axle Whine/Hum on Accel/Decel/Cruise

TSB 05-12-6

06/27/05

REAR AXLE NOISE REPAIR

FORD:
1997-2005 Expedition, F-150

2002-2005 Explorer

LINCOLN:
1998-2005 Navigator
2003-2005 Aviator

MERCURY:
2002-2005 Mountaineer

This article supersedes TSB 05-06-18 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

^ 5L2Z-4209-AA = (8.8-Inch Ring Gear/3.55 ratio) (2002-2005 Explorer/Mountaineer/Aviator)

^ 5L3Z-4209-A = (8.8-Inch Ring Gear Ring Gear/3.31 ratio) (1997-2005 F-150)

^ 5L3Z-4209-B = (8.8-Inch Ring Gear Ring Gear/3.55 ratio) (1997-2005 F-150)

^ 5L3Z-4209-C = (8.8-Inch Ring Gear 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 Ring Gear
/3.31 ratio) (1997-2005 F-150, 2005
Expedition/Navigator, 1997-2002
Expedition/Navigator)

^ 5L3Z-4209-E = (9.75-Inch Ring Gear Ring Gear/3.55 ratio) (1997-2005 F-150, 1997-2002 Expedition/Navigator)

^ 5L3Z-4209-F = (9.75-Inch Ring Gear Ring Gear/3.73 ratio) (1997-2005 F-150, 1997-2005 Expedition/Navigator)


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.

^ 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-S1OO - Differential Slave Pin Bolt (9.75" axles)

^ 387426-S1OO - 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

051206A 1997-2002 Expedition, 4.7 Hrs.
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)

051206A 2003-2005 Expedition: 5.8 Hrs.
Rear Axle Noise Repair
(Includes Time For Road
Test To Verify Concern (irs
Axle)) (Do Not Use With
4010D Or 4010D4)

051206A 2003-2005 5.9 Hrs.
Expedition/Navigator With
Air Suspension: Rear Axle
Noise Repair (Includes
Time For Road Test To
Verify Concern (lrs Axle))
(Do Not Use With 4010D
Or 4010D4)

051206A 2002-2005 6.6 Hrs.
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)

DEALER CODING
CONDITION
BASIC PART NO. CODE
4209 14
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Old 07-26-2006, 16:06   #3 (permalink)
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Exclamation Re: 2003 Mercury Mountaineer Rear End Noise

I hope anyone with a Navigator, Mountaineer, or Explorer with the common rear axle noise, has better luck with his or her dealer pursuing the problem than my Wife and I. We purchased a used 1 1/2 year old 2003 Mercury Mountaineer AWD 4.0 V6 in June of 2004, with 22,000 miles on the odometer through our local Ford dealer. Approximately 22,300 miles into our ownership we experienced a howl like noise at the front of the vehicle. Under factory mileage warranty, the dealership diagnosed a faulty front wheel bearing. They replaced with no hassle. This is a vehicle that my wife accumulates total mileage running to and from work. Fast forward to January 23, 2006. Our Mercury Mountaineer AWD now has 42,777 miles on the odometer with no towing within our ownership. My Wife and I noticed a low pitch growling noise starting at 25-30 mph and becoming higher in pitch at higher speeds. Doing some investigating on the Internet, we located a list of Technical Service Bulletins or TSB's as they are referred to. To our finding, Ford has dealt with an on-going rear axle issue on the 2002 thru 2005 Lincoln Navigator, Ford Explorer and Mercury Mountaineer's. We went to our local Lincoln / Mercury dealer to have the Service Advisor take a ride with us to listen to our vehicle sitting in the third row seat as we drove around. He heard the growl as we did, saying it sounds like a loud bearing in the axle. He mentioned there were (TSB, s) on our vehicle pertaining to our problem. Our concern was that the vehicle was approximately 6,800 miles beyond the factory mileage warranty. The Service Advisor had us bring in the Mountaineer to verify the mechanical problem. He got back to us the next business day by phone forwarding us this information... "The shop would service the axle with new and improved ring and pinion set, followed with new axle bearings and seals. This included changing the gear lubricant to 75-140w, which was another TSB. Mercury said they would be able to warranty the axle rebuild work performed by the dealership not by mileage surpassed, but by the sales date the Mountaineer was sold new from the dealership lot, i.e.. first new day of sale to current day of needed service. This date would be within the factory 36-month time frame. The dealership did ask us to work with them by paying $200.00 towards the repair bill, which we did. We made the appointment to drop off our vehicle. In two work days and a weekend the job was done, so we thought. We went to pick up our vehicle. The Service Advisor mentioned to us, there was still a noise coming from the rear of the vehicle. He blamed this due to all 4-factory Good Year tires showing 4/32nd to 6/32nd's average tread depth and needing replaced. We replaced these tires 4,500 miles later with Michelins, when we could afford them. This did not help our bearing growl problem at all. My Wife and I went back to the Lincoln / Mercury dealership on Friday (July 21st, 2006) to state our still existing problem. The Service Manager took a ride with us sitting in the middle row of seats. We took him out to the nearest highway so he could hear the same existing bearing growl we complained about at 42,777 miles. The Service Manager stated, " It sounds like the rear axle is noisy." Can you sway the vehicle left to right? I learned by doing this, he could determine if it was an outer wheel bearing going out at the rear axle. He said the culprit bearing would growl a little louder under load if it was failing. We tried this with him not noticing any apparent change in pitch of sound. The Service Manager said at this time, " sounds like it may still be a rear axle issue and I'll have to get a hold of my District Manager to see if we want to replace the entire axle housing and new gear-set." He asked us if we could bring in the vehicle the following Monday (July 24th, 2006). We dropped off the Mercury the next day. The Mountaineer was obviously out of mileage warranty and dated warranty. We hoped they would take care of an existing issue that was present when still under warranty then and still existed today out of warranty. We received a call the next day from the Service Manager stating " we put your Mountaineer up on the rack and used a stethoscope. We think it is the left rear outer wheel bearing making the majority of noise. The right bearing is making slight noise. We would like to install the rear driver side outer bearing and retest. This will run $270.00 parts and labor". We did not take our Mercury Mountaineer back to the dealership to have an on-going issue tested using our money and no longer willing to resolve Mercury's problem, which is still our problem. Any comments about a similar issue would be greatly appreciated.
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Old 07-26-2006, 19:39   #4 (permalink)
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Re: 2003 Ford Expedition Rear End Noise

A rear outer bearing will not really change pitch on a turn. I found this TSB#05-25-8..................

This article supersedes TSB 05-17-10 to update the Service Procedure.

ISSUE:
Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a noise from the rear wheel hub bearings. Previous service procedures required service replacement of the wheel hub bearing assembly, base part (1109). This new service procedure allows replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise condition.

ACTION:
Replace the rear hub bearing and wheel bearing retainer ring.
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Old 11-12-2008, 18:17   #5 (permalink)
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Re: 2003 Ford Expedition Rear End Noise

I have a 2004 Expedition purchased new November 2003 and have had rear end replaced twice on warranty. Now that I have 75,000 miles, Ford won't cover on warranty even though latest rear end has only 50,000 miles. Any suggestions?
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Old 11-20-2008, 13:40   #6 (permalink)
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Re: 2003 Ford Expedition Rear End Noise

Quote:
Originally Posted by dsblackburn View Post
I have a 2004 Expedition purchased new November 2003 and have had rear end replaced twice on warranty. Now that I have 75,000 miles, Ford won't cover on warranty even though latest rear end has only 50,000 miles. Any suggestions?
I'd persist at the dealer, or contact Ford directly with the problem. It's obvious with all the TSB's that are floating around that it's a known problem. If they won't cover it go aftermarket, DON'T get another Ford unit. There are plenty of aftermarket companies that will not only offer a superior axle assembly, but will install it at the same if not, lower price than what the dealer would charge. Yukon Gear has some good setups. Do a search and you'll find tons of options. If you have a 4x4 make sure that the axle ratio you buy is the same as the front.
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