Attachment III - Technical Information

OVERVIEW





This program involves inspecting the rear axle build label on the affected vehicles. Based on the information found complete one of the following:

^ Release the vehicle.

^ Replace the rear axle fluid. Replace the rear axle.

INSPECTION

1. Raise the vehicle on a hoist.





2. Locate the rear axle build label. See Figure 1.





3. Locate and identify the assembly line identification letter on the label. See Figure 2.

^ If the assembly line identification letter is an "E", proceed to Step 4.

^ If the assembly line identification letter is NOT an "E", no further action is required. Lower and release the vehicle.

4. Locate and identify the Julian date code on the label. See Figure 2.

^ If the Julian date code falls within the range of 04088 through 04104, proceed to Step 5.

^ If the Julian date code does NOT fall within the range of 04088 through 04104, no further action is required. Lower and release the vehicle.

5. Check the mileage of the vehicle.

^ If the vehicle has been driven less than 17 miles, the rear axle lubricant must be replaced. Perform the Rear Axle Lubricant Replacement procedure.

^ If the vehicle has been driven 17 or more miles, the rear axle assembly must be replaced. Perform the Rear Axle Assembly Replacement procedure.

REAR AXLE LUBRICANT REPLACEMENT

1. Remove the axle drain plug and allow the lubricant to drain from the axle.

2. Install the drain plug and tighten it to 95 Nm (70 lb-ft).

3. Remove the fill plug.

4. NOTE: If the vehicle is equipped with a limited slip rear axle, add 4 oz. of friction modifier (C8AZ-19B546-A (XL-3)) to the axle before installing the lubricant.

NOTE:
The rear axle build label will indicate whether or not the axle is a limited slip or a conventional axle. The last four digits indicate axle size and type. The letter "L" indicates limited slip and the letter "C" indicates a conventional axle. See Figure 2.

Fill the axle to the bottom of the fill plug hole with Motorcraft SAE 75W-140 High Performance Rear Axle Lubricant (XY-75W140-QL).

5. Install the fill plug and tighten it to 34 Nm (25 lb-ft).

6. NOTE: To fill the rear axle to the proper level, an additional pint of fluid must be added through the ABS sensor hole at the top of the axle assembly.

NOTE:
If the vehicle is not equipped with anti-lock brakes (ABS), there will be a plug in place of the rear axle ABS sensor.





Remove the rear axle ABS sensor, or plug, located on the top of the rear axle. See Figure 3.

7. CAUTION: The suction gun used to install the lubricant into the axle must be clean of any fluid residue.

Using a clean suction gun, add one pint of lubricant through the ABS sensor hole.

8. Install the rear axle ABS sensor, or plug, and tighten the bolt to 27 Nm (20 lb-ft).

REAR AXLE ASSEMBLY REPLACEMENT

1. Replace the rear axle assembly. For additional information, refer to Section 205-00 in the 2004 Explorer/Mountaineer or Aviator workshop Manual.