Drivetrain - Rear Axle Seal(s) Leaking
TSB 08-19-309/29/08
UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL
SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8
IRS, AND 9.75 IRS AXLES
FORD:
2002-2008 Explorer
2003-2008 Expedition
2006-2008 Explorer Sport Trac
LINCOLN:
2003-2005 Aviator
2003-2008 Navigator
MERCURY:
2002-2008 Mountaineer
This article supersedes TSB 06-22-05 to update the model years, Part List and Service Procedure.
ISSUE
Some 2006-2008 Expedition, Navigator, Explorer, Explorer Sport Track, and Mountaineer vehicles equipped with rear axle unitized cartridge seal, 2007-2008 Expedition-Navigator AWD equipped with front and rear axle unitized cartridge seal.
2003-2005 Expedition-Navigator, 2002-2005, Explorer-Mountaineer, 2003-2005 Aviator equipped with unitized cartridge rear axle seal, may exhibit oil separation from the internal lube found in the unitized cartridge seal. This oil separation appears to be, and is often misdiagnosed, as an axle lube leak. The majority of the vehicles with this condition will be located in northern Canada and Alaska due to the extreme cold weather.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
DO NOT REPLACE THE UNITIZED CARTRIDGE SEAL UNTIL YOU COMPLETE THIS DIAGNOSTIC SERVICE PROCEDURE. FAILURE TO PROPERLY DIAGNOSE THE ISSUE MAY RESULT IN UNNECESSARILY REPLACING THE SEAL, RESULTING IN A REPEAT CONCERN.
NOTE
THIS DIAGNOSTIC PROCEDURE IS ONLY NECESSARY ON VEHICLES WITH THE NEW UNITIZED CARTRIDGE SEAL. THIS SEAL HAS BEEN USED IN PRODUCTION FROM 2006 MODEL YEAR TO PRESENT, HOWEVER, SOME VEHICLES BUILT PRIOR TO 2006 MODEL YEAR MAY HAVE THIS NEW UPDATED UNITIZED CARTRIDGE SEAL INSTALLED AS A SERVICE
REPAIR.
1. Raise vehicle, refer to Workshop Manual (WSM), Section 100-02.
NOTE
IF SEAL IS OLD DESIGN RADIAL LIP SEAL STYLE, (SEE FIGURES 1 AND 2 TO IDENTIFY RADIAL LIP SEAL) THERE IS NO INTERNAL GREASE PRESENT IN SEAL TO SEPARATE. THIS TSB DOES NOT APPLY. REFER TO WORKSHOP MANUAL DIAGNOSTIC.
2. Check axle half shaft seal to ensure that it is unitized cartridge design.
3. Clean axle housing around the seal area using Motorcraft� Metal Brake Parts Cleaner or equivalent cleaner. Wipe lube or oil with rag and let the housing dry.
4. Add 0.5 to 1 ounce (14.8 to 29.6 ml) Rotunda Dye-Lite� Leak Detection Dye for Gasoline Engine Oil 164-R3700, also contained in 164-R0756 to the axle following the appropriate Workshop Manual.
NOTE
ADDING THE DYE ON SOME VEHICLES WILL REQUIRE THE REAR WHEEL ABS SPEED SENSOR TO BE REMOVED. REFER TO THE APPROPRIATE WORKSHOP MANUAL DRAIN AND FILL PROCEDURE.
5. Road test vehicle a minimum distance 15 miles (24 km) at a minimum speed of 25 MPH (40 Km/h).
NOTE
A BRIGHT ORANGE AREA WILL IDENTIFY AXLE LUBE LEAK. FOR EXTREMELY SMALL OIL SEPARATION, ADDITIONAL AXLE OPERATION TIME MAY BE REQUIRED FOR THE LEAK TO APPEAR.
6. Raise vehicle to check for signs of leak.
a. Use Rotunda 12V Master UV Leak Detector Kit 164-R0756 or equivalent to look for signs of leak.
7. If there is not a verifiable lube leak, clean axle near seal area and return the vehicle to the customer.
NOTE
IF THERE IS NO SIGNS OF LUBE LEAK, THIS MEANS THAT THE SUBSTANCE WHICH WAS PRESENT PRIOR TO THE PROCEDURE WAS OIL WHICH HAD SEPARATED FROM THE GREASE INTERNAL TO THE SEAL. THIS OIL IS A PRE-LUBE, AND IS NOT NECESSARY ONCE THE AXLE SEAL IS BROKEN IN. ONCE THE OIL SEPARATION HAS OCCURRED, THERE SHOULD BE NO FURTHER OIL SEPARATION FROM THE SEAL. REMOVING THE SEAL AND INSTALLING A NEW SEAL MIGHT CREATE A SITUATION WHERE THE OIL WILL SEPARATE, RESULTING IN THE SAME CONCERN.
8. If there is a verifiable axle lube leak, replace seal following the Workshop Manual (WSM), Section 205, or look at instruction sheet included in Axle Shaft Seal Kit.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
081903A 2003-2008 Expedition, 0.9 Hr.
Navigator: INSPECT Axle
Seal Leaks. Includes Time
to Add Oil Dye and Road
Test. This Labor Operation
Can Be Claimed With Any
Of The Labor Operations
In This Article. (Do Not
Use With 4139A, 4139A2)
081903A 2002-2008 Explorer, 0.7 Hr.
Mountaineer, 2007-2008
Explorer Sport Trac,
2002-2005 Aviator:
INSPECT Axle Seal Leaks.
Includes Time to Add Oil
Dye and Road Test. This
Labor Operation Can Be
Claimed With Any Of The
Labor Operations In This
Article. (Do Not Use With
4139A, 4139A2)
081903B 2003-2008 Expedition 1.3 Hrs.
Navigator: Replace Front
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. One
Side. This Labor Operation
Can Be Claimed With A,
D, Or E (Do Not Use With
4139A, 4139A2)
081903C 2003-2008 Expedition 2.2 Hrs.
Navigator: Replace Front
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. Both
Sides. This Labor
Operation Can Be Claimed
With A, D, Or E (Do Not
Use With 4139A, 4139A2)
081903D 2003-2008 Expedition, 0.7 Hr.
Navigator: Replace Rear
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. One
Side. This Labor Operation
Can Be Claimed With A,
B, Or C (Do Not Use With
4139A, 4139A2)
081903D 2006-2008 Explorer, 1.1 Hrs.
Mountaineer, 2007-2008
Explorer Sport Trac
:Replace Rear Axle Stub
Shaft Seal. Includes Time
To Remove and Install
Halfshaft. One Side. This
Labor Operation Can Be
Claimed With A (Do Not
Use With 4139A, 4139A2)
081903D 2002-2005 Explorer, 0.9 Hr.
Mountaineer:Replace Rear
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. One
Side. This Labor Operation
Can Be Claimed With A
(Do Not Use With 4139A,
4139A2)
081903D 2003-2005 Aviator:Replace 0.8 Hr.
Rear Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. One
Side. This Labor Operation
Can Be Claimed With A
(Do Not Use With 4139A,
4139A2)
081903E 2003-2008 Expedition, 1.2 Hrs.
Navigator: Replace Rear
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. Both
Sides. This Labor
Operation Can Be Claimed
With A, B, Or C (Do Not
Use With 4139A, 4139A2)
081903E 2006-2008 Explorer, 2.1 Hrs.
Mountaineer, 2007-2008
Explorer Sport Trac
Replace Rear Axle Stub
Shaft Seal. Includes Time
To Remove and Install
Halfshaft. Both Sides. This
Labor Operation Can Be
Claimed With A (Do Not
Use With 4139A, 4139A2)
081903E 2002-2005 Explorer, 1.5 Hrs.
Mountaineer: Replace Rear
Axle Stub Shaft Seal.
Includes Time To Remove
and Install Halfshaft. Both
Sides. This Labor
Operation Can Be Claimed
With A (Do Not Use With
4139A, 4139A2)
081903E 2003-2005 Aviator: 1.6 Hrs.
Replace Rear Axle Stub
Shaft Seal. Includes Time
To Remove and Install
Halfshaft. Both Sides. This
Labor Operation Can Be
Claimed With A (Do Not
Use With 4139A, 4139A2)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4A109 42
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