Ford Ecosport: Rear Drive Axle/Differential / Diagnosis and Testing - Rear Drive Axle and Differential

Ford Ecosport 2014-2024 Service and Repair Manual / Driveline / Rear Drive Axle/Differential / Diagnosis and Testing - Rear Drive Axle and Differential

Preliminary Inspection

Visually inspect the housing, seals, and pinion flange for obvious signs of mechanical damage.

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step

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	Possible Sources	Actions
Axle howling or whine	Axle lubricant low	CHECK the lubricant level. FILL the axle to specification. REFER to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
	Axle housing damage	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation). INSPECT and INSTALL new rear differential subframe bushings as necessary. REFER to: Differential Rear Bushing (205-02 Rear Drive Axle/Differential, Removal and Installation).
	Damaged, worn or incorrect ring and pinion gear contact	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Driveline clunk - loud clunk when shifting from REVERSE to DRIVE	Incorrect axle lubricant level	CHECK the lubricant level. FILL the axle to specification. REFER to: Differential Fluid Level Check (205-02 Rear Drive Axle/Differential, General Procedures).
	Excessive backlash in the axle	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).
Driveline clunk — occurs as the vehicle starts to move forward following a stop	Loose rear axle mount	CHECK for loose bolts. TIGHTEN to specifications. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
	Extended front to rear tire size differentiation	PERFORM AWD functional test (Pinpoint test A). REFER to: Four-Wheel Drive Systems (308-07A Four-Wheel Drive Systems, Diagnosis and Testing).
Grinding, popping or chattering – noise from the rear axle when the vehicle is turning	Damaged RDU clutch - discs fused from two-wheel or extended front to rear differentiation	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).
	Damaged or worn differential (differential side gears and pinion gears)	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Grunting — normally associated with a shudder experienced during acceleration from a complete stop	Loose rear axle mount bolts or suspension fasteners	CHECK for loose bolts. TIGHTEN to specifications. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Howl – can occur at various speeds and driving conditions. Affected by acceleration and deceleration	Incorrect ring and pinion contact, incorrect bearing preload or gear damage	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Chuckle – heard at coast/ deceleration. Also described as knock	Incorrect ring and pinion contact or damaged teeth on the coast side of the ring and pinion	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Knock – noise occurs at various speeds. Not affected by acceleration or deceleration	Gear tooth damage to the driver side of the ring and pinion	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Scraping noise – a continuous low pitched noise starting at low speed	Worn or damaged pinion bearings	INSPECT and INSTALL a new axle assembly as necessary. REFER to: Axle Assembly (205-02 Rear Drive Axle/Differential, Removal and Installation).
Driveline shudder – occurs during acceleration from a slow speed or stop	Rear drive axle assembly mispositioned	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).
	Loose rear axle bolts	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).
	Driveline angles out of specification	CHECK for correct driveline angles. REFER to: Driveshaft Angle Measurement (205-01 Driveshaft, General Procedures).

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).
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Specifications

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...

General Procedures - Active On-Demand Coupling Configuration

Configuration Using the diagnostic scan tool, under the toolbox icon select powertrain then select active on demand coupling barcode Entry...

Other information:

Ford Ecosport 2014-2024 Service and Repair Manual: Description and Operation - Transfer Case - Overview

Overview NOTE: Serviceability of the transfer case is limited to seals and the output flange. If any of the geared components, bearings, cases, covers or internal shafts fail, a new transfer case must be installed. The transfer case is a gearbox that attaches to the transmission...

Ford Ecosport 2014-2024 Service and Repair Manual: Removal and Installation - Transfer Case Input Shaft Seal LH

Special Tool(s) / General Equipment 205-153 (T80T-4000-W) Handle 308-878Installer, Input SealTKIT-2012A-FLTKIT-2012A-ROW Removal Remove the PTU/transfer case. Refer to: Transfer Case (308-07 Transfer Case - 6-Speed Automatic Transmission - 6F35) ...

Removal and Installation - Rear Halfshaft Seal

Special Tool(s) / General Equipment

205-153 (T80T-4000-W)
Handle

205-990
Installer, Axle Seal
TKIT-2012A-FL
TKIT-2012A-ROW