Axle Hubs Not Engaging, Staying Engaged And/or Unlocking

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TSB
04-18-5

AXLE – FRONT HUBS NOT ENGAGING, NOT STAYING ENGAGED AND/OR UNLOCKING

1999-2004 F-SUPER DUTY
2000-2004 EXCURSION

This article supersedes TSB 04-11-6 to update the vehicle lines listed in the printed version of TSB 04-11-6.

ISSUE:

Some 4X4 vehicles may exhibit a hub not engaging, not staying engaged and/or unlocking. This may be due to hub lock damage caused by contact between the front axle shaft and the inside of the hub lock assembly.

ACTION:

Follow normal Workshop Manual diagnostics for four wheel drive system. If diagnostics lead to a failed hub lock, check the inside of the hub lock for signs of contact with the axle shaft (Figure 1). If signs of contact are evident, perform the following procedure when replacing the hub lock assembly.

Figure 1 – Article 04-18-5

SERVICE PROCEDURE

Remove the hub lock assembly. Refer to Workshop Manual Section 308-07A (for 1999 model year vehicles refer to 2000 Workshop Manual).
Insert clean rag into wheel hub cavity to protect it from contamination.
Drill out axle shaft pilot hole to 16 mm (5/8″) diameter and 2 mm (0.08″) deep (Figure 2). The axle shaft does not need to be removed from wheel-end assembly for this step.

Figure 2 – Article 04-18-5

NOTE: OPENING THE SHAFT PILOT HOLE DIAMETER WILL PROVIDE CLEARANCE TO THE METAL TABS, LOCATED INSIDE THE HUB LOCK, DURING ENGAGEMENT CYCLING.

Remove all contaminants from hub cavity and reassemble.

PART NUMBER	PART NAME
1C3Z-3B396-CB	Front Axle Hub (ESOF)
1C3Z-3B396-DA	Front Axle Hub (Manual)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION	DESCRIPTION	TIME
041805A	Replace Hub Lock Assembly And Drill Axle Shaft Pilot Hole (Does Not Include Time For The Diagnosis Described In The Repair Action) One Hub	0.3 Hr.
041805B	Replace Hub Lock Assembly And Drill Axle Shaft Pilot Hole (Does Not Include Time For The Diagnosis Described In The Repair Action) Both Hubs	0.5 Hr.