Mechanics

FRONT END HOWLING

2003 Ford Explorer

Noises problem
2003 Ford Explorer 6 cyl All Wheel Drive Automatic 57000 miles

I have a 2003 Ford Explorer XLT 4.0 FF with 57k on the clock. I have began to notice that when cruising, or when I am not on the throttle and free wheeling, the truck makes a howling noise, somewhat rythimic (rotational I believe). I have checked my front brakes and cleaned them, this has done nothing but dirty up a set of clothes. I have read tat it can be many problems, but I do not want to go and spend money without knowing what it is. Also, when the truck has been driven a bit, there seems to be a thud, again rythmic in nature. I have read that the rear end may be a problem, but I feel it to be the front. Bearings? Fluid issues? Also note, the tires on the front are dissimalar by the following numbers (245 65 R17, 105S, M+S and 245 65 R17, 105S, M+S, DT) Please help!
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Roman17
October 3, 2008.




There are two Tech bullitens on noise for your SUV, Here they are.
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE -2003 Ford Explorer
Page 1 of 3
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
TECHNICAL SERVICE BULLETIN
Reference Number(s): 05-16-4,  Date of Issue:   August 22, 2005 FORD: 2002-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer
Superceded Bulletin(s): 05-3-7,  Date of Issue:   February 21, 2005 Related Ref Number(s): 05-16-4, 05-3-7
ARTICLE BEGINNING
DESCRIPTION
DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE
ISSUE
NOTE: This article supersedes TSB 05-3-7 to update the service procedure and to add a vehicle line.
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 (Fig. 1 ).
Fig. 1: Driveshaft Flange Bolt
4. Remove the transfer case rear output flange bolts (Fig. 2 ).

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DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE -2003 Ford Explorer
Page 2 of 3
Fig. 2: Transfer Case Rear Output Flange Bolts
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 (Fig. 3 ).
Fig. 3: Disconnecting Driveshaft Flange
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.

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DRIVELINE 1ST ORDER VIBRATION/BOOM/DRONE -2003 Ford Explorer
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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 A CROSS 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 INFORMATION
PARTS INFORMATION Part Number 6L2Z-4602-A TA-25
WARRANTY INFORMATION
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
WARRANTY INFORMATION Operation Description 051604A 2002-2005 Explorer/Mountaineer 2003-2005 Aviator: Install EVA, Road Test To Verify Concern, Replace Driveshaft After Measuring And Adjusting Driveshaft To Specific Length (Do Not Use With 4602A, 1007D, 1007D7)
DEALER CODING Basic Part No. 4602
Part Name Driveshaft Threadlock And Sealer
Time 1.3 Hrs.
Condition Code 13

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REAR AXLE NOISE REPAIR -2003 Ford Explorer
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REAR AXLE NOISE REPAIR
TECHNICAL SERVICE BULLETIN
Reference Number(s): 05-23-3,  Date of Issue:   November 28, 2005
FORD: 1997-2005 Expedition, F-150; 2002-2005 Explorer LINCOLN: 1998-2005 Navigator; 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer
Superceded Bulletin(s): 05-12-6,  Date of Issue:   June 27, 2005 Related Ref Number(s): 05-12-6, 05-23-3, 05-6-18
ARTICLE BEGINNING
DESCRIPTION
REAR AXLE NOISE REPAIR
ISSUE
NOTE: This article supersedes TSB 05-12-6 to update the Service Kit and Service Procedure information.
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-

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REAR AXLE NOISE REPAIR -2003 Ford Explorer
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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
 5L3Z-4209-A = (8.8-Inch Ring Gear/3.31 ratio) (1997-2005 F-150)
 5L3Z-4209-B = (8.8-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 2002-2005 Explorer/Mountaineer/Aviator)
 5L3Z-4209-C = (8.8-Inch 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/3.31 ratio) (1997-2005 F-150, 2005 Expedition/Navigator, 1997-2002 Expedition/Navigator)
 5L3Z-4209-E = (9.75-Inch Ring Gear/3.55 ratio) (1997-2005 F-150, 1997-2002 Expedition/Navigator)
 5L3Z-4209-F = (9.75-Inch Ring Gear/3.73 ratio) (1997-2005 F-150, 1997-2005 Expedition/Navigator)
NOTE: 9.75 REAR AXLE HOUSINGS WERE REDESIGNED IN MID-1999, INCREASING FRONT PINION BEARING SIZE. REPLACING RING & PINIONS IN AN OLD-STYLE AXLE ASSEMBLY WILL REQUIRE INSTALLATION OF SPACER P/N YL3Z-4662-CA. SPACER IS TO BE INSTALLED BETWEEN INNER PINION BEARING AND COLLAPSIBLE SPACER.
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: 10/3/2008
REAR AXLE NOISE REPAIR -2003 Ford Explorer
Page 3 of 4
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.
 YL3Z-4662-CA - Pinion Bearing Spacer for 1997-1998 9.75 axles
 XG-14 - Gear Marking Compound
 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-S100 - Differential Slave Pin Bolt (9.75" axles)
 387426-S100 - 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 INFORMATION
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
WARRANTY INFORMATION
Operation 052303A 1997-2002 Expedition, 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) 052303A 2003-2005 Expedition: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4) 052303A 2003-2005 Expedition/Navigator With Air Suspension: Rear Axle Noise Repair (Includes Time For Road Test To Verify Concern (Irs Axle)) (Do Not Use With 4010D Or 4010D4) 052303A 2002-2005 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) Description
Time 4.7 Hrs.
5.8 Hrs.
5.9 Hrs.
6.6 Hrs.
DEALER CODING

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REAR AXLE NOISE REPAIR -2003 Ford Explorer
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Basic Part No. 4209
Condition Code 14

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Merlin2021
Oct 3, 2008.


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