Driveline - Vibration/Boom Between 55 and 75 MPH
TSB 05-16-408/22/05
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
FORD:
2002-2005 Explorer
LINCOLN:
2003-2005 Aviator
MERCURY:
2002-2005 Mountaineer
This article supersedes TSB 05-3-7 to update the service procedure and to add a vehicle line.
ISSUE
Some 2002-2005 4x4 Explorer 4dr/Mountaineer and 2003-2005 4x4 Aviator vehicles may exhibit a vibration/drone/boom at 55-75 MPH (89-121 km/h). Electronic vibration analyzer (EVA) readings will fall under 1st order rear driveshaft at 2700-3100 shaft RPM (45-52 Hertz).
ACTION
If the condition is present in 3rd gear (with overdrive cancelled), and is isolated to the driveline (not felt through the steering wheel), install a premium balanced driveshaft. Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
THIS TSB DOES NOT APPLY TO THE SOLID 4X2 DRIVESHAFT, IT ONLY APPLIES TO 4X4 WITH BOOT/SLIP JOINT IN THE MIDDLE OF THE DRIVESHAFT.
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Workshop Manual Section 100-02.
2. Remove skid plate, if equipped.
3. Remove the driveshaft flange bolts (Figure 1).
4. Remove the transfer case rear output flange bolts (Figure 2).
NOTE
THE DRIVESHAFT FLANGE FITS TIGHTLY ON THE AXLE PINION FLANGE PILOT AND THE TRANSFER CASE OUTPUT FLANGE. DO NOT HAMMER ON THE DRIVESHAFT OR ANY OF ITS COMPONENTS TO DISCONNECT THE DRIVESHAFT FLANGES FROM THE MATING FLANGES. PRY ONLY IN THE AREA SHOWN WITH A SUITABLE TOOL, TO DISCONNECT THE DRIVESHAFT FLANGES.
5. Using a suitable tool, disconnect the driveshaft flanges and remove the driveshaft (Figure 3).
6. Measure the NEW driveshaft length from u-joint center to u-joint center. Refer to Step 6a or 6b.
a. Driveshafts measuring LESS than 1194 +/- 1.0 mm must be expanded as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and expand (by pulling) as required to 1194 +/- 1.0 mm.
NOTE
DO NOT USE A BAR OR SIMILAR DEVICE BETWEEN THE FLANGE AND CARDON JOINT.
b. Driveshafts measuring GREATER than 1194 +/- 1.0 mm must be compressed as follows:
(1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice.
CAUTION
CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE.
(2) Grasp the shaft at the opposing flange with both hands and compress (by pushing) together by hand as required to 1194 +/- 1.0 mm.
NOTE
DO NOT USE A HAMMER OR SIMILAR DEVICE.
THIS MAY CAUSE DAMAGE TO THE SHAFT FLANGE.
7. To install, align the driveshaft paint markings with companion flange markings, if present.
8. Coat the bolts with Threadlock And Sealer TA-25 meeting Ford specification WSK-M2G351-A5.
NOTE
THE DRIVESHAFT FLANGES FITS TIGHTLY ON THE PINION FLANGE PILOTS. TO ENSURE THE DRIVESHAFT FLANGES SEAT SQUARELY ON THE PINION FLANGES, TIGHTEN THE DRIVESHAFT FLANGE BOLTS EVENLY IN ACROSS PATTERN.
9. Support the rear driveshaft.
10. Install flange bolts at rear axle flange by hand.
11. Install flange bolts at transfer case flange by hand.
12. Tighten all driveshaft flange bolts to 76 lb-ft (103 N.m).
13. Reinstall skid plate, if equipped.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
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