Axle - Rear Axle Cover Vent Hose Lubricant Leakage
Article No.94-11-12
AXLE - REAR - LUBRICANT LEAKAGE THROUGH COVER VENT/HOSE
FORD:
1989-94 THUNDERBIRD
LINCOLN-MERCURY:
1989-94 COUGAR
ISSUE:
Rear axle leakage may occur through the cover vent/hose because the rear axle vent tube is not positioned properly.
ACTION:
If rear axle lubricant is observed to be leaking from the vent/hose, check the position of the rear axle vent tube and, if necessary, clean and reposition it. Refer to the following procedure for service details.
1. Raise the vehicle on a hoist. Refer to the appropriate model year Thunderbird/Cougar Service Manual, Section 10-04 (1988-91) or Section 00-02 (1992-94).
2. Remove and inspect vent hose to assure it is free of dirt and/or debris. If the hose is plugged, clean or replace it.
3. Check the vent to make sure it is aligned correctly with the cover, Figure 1.
NOTE:
NOTCH IN VENT MUST ALIGN WITH NUB IN COVER.
NOTE:
USE THE FOLLOWING PROCEDURE FOR 8.80 RING GEAR ONLY. THE 7.5" RING GEAR IS NOT EQUIPPED WITH A DEFLECTOR.
4. Support the axle and remove the rear axle differential rear insulator-to-crossmember retaining bolts, Figure 2.
5. Position the drain pan under the axle. Remove axle housing cover bolts, Figure 3.
6. Remove the rear axle cover, Figure 4.
7. Remove the lubricant deflector inside of cover using 1/8" Allen wrench, Figure 5.
8. If the vent is found to be misaligned, pry it out with a screwdriver, Figure 6.
9. If the vent is damaged, replace it with a new axle vent assembly (E9SZ-4022-A).
10. Thoroughly clean all sealing surfaces and cover groove, Figure 7. Make sure there is no gasket material in or near the vent hole or lubricant deflector area.
11. Install the rear axle housing vent as shown in Figure 8.
NOTE:
THE NOTCH IN THE REAR AXLE HOUSING VENT MUST BE ALIGNED WITH THE NUB IN THE AXLE HOUSING COVER.
CAUTION:
IF THE VENT IS NOT INSTALLED AS SHOWN IN FIGURE 8, IT WILL LEAK, CAUSING OVERHEATING OF THE AXLE AND POSSIBLE COMPONENT FAILURE.
12. Seat the rear axle housing vent using a 9/32" (7.144 mm) deep well socket or similar tool to drive against the rear axle housing vent lip, Figure 9.
CAUTION:
DO NOT HAMMER ON END OF VENT TUBE.
13. Install the lubricant deflector using a 1/8" (3.175 mm) Allen wrench, Figure 10. A gap of .200" to .250" MUST exist between the end of the lubricant deflector and the back-face of the cover, Figure 11.
CAUTION:
IF SHIELD GAP IS NOT .200" to .250", IT WILL CAUSE A VENT LEAK AND AXLE OVERHEATING.
14. Apply a continuous bead of silicone rubber (D6AZ-19562-AA; ESE-M4G195-A and ESB-M4G92-A) or equivalent to groove in axle housing cover, Figure 12.
NOTE:
THE AXLE HOUSING COVER ASSEMBLY MUST BE INSTALLED WITHIN 15 MINUTES OF APPLICATION OF THE SILICONE RUBBER OR NEW SILICONE RUBBER MUST BE APPLIED.
CAUTION:
MAKE SURE MACHINED SURFACES ON BOTH AXLE HOUSING COVER AND REAR AXLE HOUSING CARRIER ARE CLEAN BEFORE INSTALLING THE NEW SILICONE RUBBER. THE INSIDE OF REAR AXLE HOUSING MUST BE COVERED WHEN CLEANING THE MACHINED SURFACE TO PREVENT REAR AXLE HOUSING CONTAMINATION. TIGHTEN THE COVER BOLTS IN A CROSSWISE PATTERN TO ENSURE UNIFORM DRAW ON AXLE HOUSING COVER.
15. Install vent house, Figure 13.
16. Position new axle housing cover retaining bolts.
a. Place the service identification tag in the 12 o'clock position.
b. Tighten the bolts to 27-37 N-m (20-27 lb.ft.).
17. Install the rear axle differential rear insulator-to-crossmember bolts, Figure 15.
a. Tighten bolts to 108-136 N-m. (80-100 lb.ft.).
b. Fill the rear axle housing with specified rear axle lubricant to 1/4" (6.35 mm) below bottom of filler hole.
18. Install filler plug, Figure 16. Tighten to 28-40 N-m (21-30 lb.ft.).
19. Ensure that vent hose is routed correctly to vehicle subframe.
LUBRICANT SPECIFICATIONS FOR CONVENTIONAL DIFFERENTIAL AXLES
Fill the rear axle with 3.50 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A.
LUBRICANT SPECIFICATIONS FOR TRACTION-LOK (LIMITED-SLIP) DIFFERENTIAL AXLES
Fill the rear axle with 3.25 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A, PLUS 4 ounces of Friction Modifier Additive (C8AZ-19B546-A), Ford Specification EST-M2C118-C.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Models
OPERATION DESCRIPTION TIME
941112A Remove And Install 1.1 Hrs.
Differential Vent Assembly
DEALER CODING
BASIC PART NO. CONDITION CODE
4022 51
OASIS CODES: 509000