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Scottdagoalie
Scottdagoalie, Senior Master Tech.
Category: Ford
Satisfied Customers: 1940
Experience:  30 years with Ford dealers
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2004 ford F 150 crew cab 4x4 Whining noise in the rear at

Customer Question

2004 ford F 150 crew cab 4x4 : Whining noise in the rear at about 50mph, noise goes away when you take foot off the gas, or drive at other speeds. Only 44,000 miles on the truck. The dealership says it needs a new bearing and clutch pack in the rear differential ( 3.63 limited slip). At $1700, this sounds excessive for a low mileage truck. Can they really diagnose this problem without taking the rear end apart ? Is there another explanation ?
Submitted: 5 years ago.
Category: Ford
Expert:  Scottdagoalie replied 5 years ago.
There is a ford tsb for your concern that states replacing worn bearings,not clutch packs. The clutch pack will not make a noise while driving on a striaght road.It may cause a chatter at low speed turns only.
The problem can be diagnosed by driving, but will need disassembling to find out which bearings need replacing. Generally the bearing and seal replacement jobs we do run around $800-$950. Depending on how many bearings need replacing and labor rate .I'm attaching the TSB as it reads,it clearly points out replace only the parts that are needed.
Hope it helps.

TSB 05-23-3
FORD:
1997-2005 Expedition, F-150
2002-2005 Explorer
LINCOLN:
1998-2005 Navigator
2003-2005 Aviator
MERCURY:
2002-2005 Mountaineer

 

This article supersedes TSB 05-12-6 to update the Service Kit and Service Procedure information.

ISSUE:

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-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:

 

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)
Expert:  Scottdagoalie replied 5 years ago.
Have you had any luck on fixing your rear end issue? Let me know if I can provide you with any further assistance. Thank yo
Scottdagoalie, Senior Master Tech.
Category: Ford
Satisfied Customers: 1940
Experience: 30 years with Ford dealers
Scottdagoalie and 11 other Ford Specialists are ready to help you
Customer: replied 5 years ago.
Answer was accepted-thanks for your advice. Some ford owners have experienced a quick fix for this problem by changing out the diff fluid to the fresh synthetic oil with 2 tubes of limited slip additive. Any chance this will work ?.....Customer.
Expert:  Scottdagoalie replied 5 years ago.
Usually changing the fluid will help if the noise is related to turns,not accelerating.
Thanks for accepting my answer!

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