Spell check and are not friends.  I have no clue what Calcification on rear
axle noise is.   It should read something like clarification.

/Richard

Hey! You just described my 2004. It went out of warrenty last month.
Should I be worried?

dickm

Nope, you've got the whine

When you take your foot off the gas you take the load off the bearings

Better hurry !!!!!!!!!!!

TSB 05-23-3 11/28/05

REAR AXLE NOISE REPAIR\

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 YL3Z4662-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)
- W710084-5439 - Wheel End Nuts
- 390266-S199 - 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 STATUS: Eligible Under Provisions Of New Vehicle Limited
Warranty Coverage
OPERATION       DESCRIPTION                     TIME

052303A         1997-2002 Expedition,           4.7 Hrs.
                       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:           5.8 Hrs.
                       Rear Axle Noise Repair
                       (Includes Time For Road
                       Test To Verify Concern (lrs
                       Axle)) (Do Not Use With
                       4010D Or 4010D4)

052303A         2003-2005                              5.9 Hrs.
                       Expedition/Navigator With
                      Air Suspension: Rear Axle
                      Noise Repair (Includes
                     Time For Road Test To
                     Verify Concern (lrs Axle))
                     (Do Not Use With 4010D
                     Or 4010D4)

052303A         2002-2005                       6.6 Hrs.
                       Explorer/Mountaineer,
                       2003-2005 Aviator: Rear
                       Axle Noise Repair
                       (Includes Time For Road
                        Test To Verify Concern (lrs
                       Axle)) (Do Not Use With
                       4010D Or 4010D4)

DEALER CODINGCONDITION BASIC PART NO.CODE 420914

OASIS CODES: 509000, 590000, 597997, 702000, 702200, 703200, 703300,
703400,
790000

I called the local Ford store and they said it sounds like the bearings to
them.  They will test drive to confirm the problem then order the parts.
 I will let everyone know how it all comes out!

/Richard

The local FORD store (where I bought the last 3 vehicles from)  asked me to
come in Saturday morning at 7:30 so the service guy could verify the
problem.  They feed me a sausage biscuit and had me on my way by 8:00.
  They are ordering the bearing kit or whatever to install as soon as it
comes in.   Looks good so far.......

/Richard

This is an inherent design problem with many Fords. I have a 2002 F-150 with
the same thing. Took it to the dealer, under warranty, who inspected it and
said everything was OK. But it still whines 40K later. My wife's 2004 Sport
Trac has the same problem. This is one reason why Ford is loosing market
share to Toyota and everyone else. They won't do what they need to do to put
these kind of problems to bed.
I don't believe it has anything to do with the bearings. I believe it has to
do with an improper meshing of the ring and pinion gears. My truck now has
57K on it and the noise is the same.
Ron

Going in Tuesday to get the repair done.  They said to plan on leaving it
all day.

/Richard

Well it really went in today to the shop. 07/05/06  warranty expires
07/31/06.  They did not have a loaner car for my wife so the service manager
took her home.  Which was pretty nice of them.
    Is there any particular "test" that can be done to make sure everything
is OK, or at least not worse?

Thanks
Richard