Ford Ecosport: Rear Drive Axle/Differential / Diagnosis and Testing - Rear Drive Axle and Differential
Preliminary Inspection
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Visually inspect the housing, seals, and pinion flange for obvious signs of mechanical damage.
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If an obvious cause for an observed or reported concern is
found, correct the cause (if possible) before proceeding to the next
step
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If the cause is not visually evident, verify the symptom and REFER to Symptom Chart: NVH .
Symptom Chart(s)
Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).
Symptom Chart: NVH
Symptom Chart
Condition
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Possible Sources
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Actions
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Axle howling or whine
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CHECK the lubricant level. FILL the axle to specification.
REFER to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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INSPECT and INSTALL new rear differential subframe bushings as necessary.
REFER to: Differential Rear Bushing (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Damaged, worn or incorrect ring and pinion gear contact
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Driveline clunk - loud clunk when shifting from REVERSE to DRIVE
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Incorrect axle lubricant level
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CHECK the lubricant level. FILL the axle to specification.
REFER to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
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Excessive backlash in the axle
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CHECK for excessive axle backlash. INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Driveline clunk — occurs as the vehicle starts to move forward following a stop
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CHECK for loose bolts. TIGHTEN to specifications.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Extended front to rear tire size differentiation
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PERFORM AWD functional test (Pinpoint test A).
REFER to: Four-Wheel Drive Systems (308-07A Four-Wheel Drive Systems, Diagnosis and Testing).
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Grinding, popping or chattering – noise from the rear axle when the vehicle is turning
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Damaged RDU clutch - discs fused
from two-wheel or extended front to rear differentiation
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TEST and INSTALL a new active torque coupling clutch as necessary.
REFER to: Four-Wheel Drive Systems (308-07A Four-Wheel Drive Systems, Diagnosis and Testing).
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Damaged or worn differential (differential side gears and pinion gears)
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Grunting — normally associated with a
shudder experienced during acceleration from a complete stop
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Loose rear axle mount bolts or suspension fasteners
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CHECK for loose bolts. TIGHTEN to specifications.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Howl – can occur at various speeds and
driving conditions. Affected by acceleration and deceleration
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Incorrect ring and pinion contact, incorrect bearing preload or gear damage
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Chuckle – heard at coast/ deceleration. Also described as knock
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Incorrect ring and pinion
contact or damaged teeth on the coast side of the ring and pinion
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Knock – noise occurs at various speeds. Not affected by acceleration or deceleration
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Gear tooth damage to the driver side of the ring and pinion
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Scraping noise – a continuous low pitched noise starting at low speed
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Worn or damaged pinion bearings
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INSPECT and INSTALL a new axle assembly as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Driveline shudder – occurs during acceleration from a slow speed or stop
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Rear drive axle assembly mispositioned
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CHECK the axle mounts and the rear suspension for damage or wear. Repair as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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CHECK the rear axle for loose bolts. TIGHTEN the bolts as necessary.
REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
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Driveline angles out of specification
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CHECK for correct driveline angles.
REFER to: Driveshaft Angle Measurement (205-01 Driveshaft, General Procedures).
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Analysis of Leakage
Clean up the leaking area enough to identify the exact source.
A plugged Rear Drive Unit (RDU) housing vent can cause excessive pinion seal lip wear due to internal pressure buildup.
Verify the RDU lubricant level is even or flush with the bottom of the fill hole.
Axle Vent
A
plugged vent will cause excessive seal lip wear due to internal
pressure buildup. If a leak occurs, check the vent. If the vent cannot
be cleared, install a new vent.
Drive Pinion Seal
The drive pinion seal is not serviceable. If a leak is present from the drive pinion seal a new RDU must be installed.
Differential Seals
NOTICE:
When installing shafts, do not allow splines to contact seals during installation or damage to the seals may occur.
Halfshaft
pilot bearing housing seals are susceptible to the same types of damage
as drive pinion seals if incorrectly installed. The seal bore must be
clean and the lip handled carefully to avoid cutting or tearing it. The
seal journal surface must be free of nicks, gouges and rough surface
texture.
For information on differential seals,
REFER to: Rear Halfshaft Seal (205-02 Rear Drive Axle/Differential, Removal and Installation).
.
Materials
Name
Specification
Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant
WSP-M2C197-A
Capacities
Item
Liters
Motorcraft® SAE 80W-90 Premium Rear Axle Lubricant
0...
Configuration
Using the diagnostic scan tool, under the toolbox icon
select powertrain then select active on demand coupling barcode Entry...
Other information:
Removal
NOTE:
Removal steps in this procedure may contain installation details.
Remove the cowl panel grille.
Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
Detach the retainer and position the inlet manifold to brake booster vacuum pipe...
Removal
NOTE:
Removal steps in this procedure may contain installation details.
NOTE:
LH side shown, RH side similar.
NOTICE:
Only use moderate force.
Using a non-marring trim removal tool, disengage the retainer clips, release adhesive tape and remove moulding...