Blew an axle seal

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License2Bill

New member
I noticed a blown axle seal on the passenger side of my 2003 300A (build date 10-4-02) the other day and haven't driven it since. Prior to this, I had been hearing a noise that varied in frequency as the speed of the vehicle changed.

I used the search function and was able to find the TSB number 03-05-05, but that apparently only applies to vehicles under 36,000 and something about a Ford recall 04S16, which states bad bearings and improper lubrication could lead to axle failure in Crown Vics and Town Cars. Dealers were instructed to install p/n 3W1Z-4A109-AA Rear Axle Bearing Service kit, which consists of new axles, bearings, seals and 75w-140 gear oil.

I was just quoted $1100 + tax to have this taken care of at a stealership, seems pretty steep to me. Has anybody ever had this work done without paying that much (meaning for free or just a deductible) out of pocket?
 
License2Bill said:
I noticed a blown axle seal on the passenger side of my 2003 300A (build date 10-4-02) the other day and haven't driven it since. Prior to this, I had been hearing a noise that varied in frequency as the speed of the vehicle changed.

I used the search function and was able to find the TSB number 03-05-05, but that apparently only applies to vehicles under 36,000 and something about a Ford recall 04S16, which states bad bearings and improper lubrication could lead to axle failure in Crown Vics and Town Cars. Dealers were instructed to install p/n 3W1Z-4A109-AA Rear Axle Bearing Service kit, which consists of new axles, bearings, seals and 75w-140 gear oil.

I was just quoted $1100 + tax to have this taken care of at a stealership, seems pretty steep to me. Has anybody ever had this work done without paying that much (meaning for free or just a deductible) out of pocket?
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Can probably find a local shop to do it for less. Get recommendations from friends, relatives, etc., also check with the local mustang clubs in your area for recommendations.
 
It's not that hard to do yourself. The whole job shouldn't take more than a couple hours. The parts are the expensive stuff, but the axle shafts shouldn't be more then $300 for the pair, and the bearings, seals, and oil doesn't add up to more than another $100. So, $400 in parts, and assume a minimum job rate of 3 hours. Even at $100/hr, that's another $300. $700-$800 for the whole job would be reasonable.

I'm guessing you're getting ripped off on the axle shafts. I'll bet Ford wants a king's ransom for those.
 
I've tried doing axle seals and bearings on my Crown Vic, didn't seat the bearing correctly, they came apart in the housing and actually wore the end of the tube into a tear drop shape. That was a $2500 fix to get a new rear end installed.

I forgot to add, the $1100 was with a diff clutch repack as well. Still seems high to me.
 
The bearings and seals will be exactly the same on the MM as it is on the CV. I'll bet you know what you did wrong the first time and would be unlikely to make the same mistake again. But if you have the money and want peace of mind, the stealership is definitely the way to go.

The LSD re-pack is a real PITA. That adds another couple hundred. The actual rebuild kit from Ford is only about $60, but it's a lot of work, and if done wrong will make a lot of noise and not work properly.
 
Peteyg said:
But if you have the money and want peace of mind, the stealership is definitely the way to go.
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I'm having to borrow from my room mates (read parents) to pay for this repair. A friend of a friend has his own shop, but definitely seems a little on the shady side. I supply the parts, pay him cash only, no credit cards. $250 max though on the labor.
 
License2Bill said:
A friend of a friend has his own shop, but definitely seems a little on the shady side. I supply the parts, pay him cash only, no credit cards. $250 max though on the labor.
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A rear end is not the place to have some yokel who does not know what they're doing messing around. No offense to your shady friend. :D

The rear ends on these cars only last around 100K before needing new axles, clutches, seals. Heck, call it a complete rebuild as you may as well change the carrier bearings while you're in there.

Car maintenance co$t$, and you just came due for a major one. Good luck. The best thing you can do is to find a shop that specializes in rear end work and get it fixed right. Or do it yourself. But you have to do it right . . .
 
Buy the kit and do it yourself. Its super easy doing rear end work.

My 03' **** the bed with its axles too. Happened around 45k. They were grooved BAD.
 
Vortech347 said:
Buy the kit and do it yourself. Its super easy doing rear end work.
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Let's not over-simplify. OP tried this once before and failed. Yes, the axles by themselves are straightforward enough. But very few axle assemblies need axles only once they have been run long enough to see this failure.

Typically limited slip clutches (or just replace the entire carrier), carrier and pinion bearings and seal, and complete tear down to clean out all the metal shavings are required. Proper re-assembly requires setting the contact pattern, pinion depth and backlash.

While it is possible for the average person to do this using care and access to the proper tools and parts, it is not trivial. Any errors will result in noise and rapid wear.
 
You don't have to "set" anything up. Its like lego's. I guess I've just done it to many times on Ford rear ends and its like changing shirts to me. LOL
 
I'm only guessing that it needs a clutch repack at this point. The last time I did a burnout, it resulted in a one wheel peel, which to me seems to mean burnt diff clutches.

Could I buy p/n 3W1Z-4A109-AA Rear Axle Bearing Service kit, have it installed and leave the clutches alone until I can afford to have them done?
 
Blew an axle seal

Is the axle seal only native to CT? Cause out here we have Harbor seals and fur seals but I've never heard of a axle seal.. Lol
 
License2Bill said:
I'm only guessing that it needs a clutch repack at this point. The last time I did a burnout, it resulted in a one wheel peel, which to me seems to mean burnt diff clutches.

Could I buy p/n 3W1Z-4A109-AA Rear Axle Bearing Service kit, have it installed and leave the clutches alone until I can afford to have them done?
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At 120K miles it not only needs clutches but a complete rebuild. I understand money is tight, but your axle doesn't care.

The problem with just stuffing new axles in it is there is likely a significant amount of metal ground up in the oil from the failed axles/bearings and it hasn't done the rest of the parts in there any good. You need to clean it all out and replace ALL the bearings and seals.

Unless labor is free, it is not that cost effective to dig into it twice. Personally, even if it is my own labor, I never consider it "free". I hate doing things twice when I could have done it correctly once.
 
Vortech347 said:
You don't have to "set" anything up. Its like lego's. I guess I've just done it to many times on Ford rear ends and its like changing shirts to me. LOL
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I call BS. Replacing carrier and pinion bearings requires ring and pinion setup. But if you like to just slap it together in your car, go ahead . . .
 
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lifespeed said:
The rear ends on these cars only last around 100K before needing new axles, clutches, seals.
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lifespeed said:
At 120K miles it not only needs clutches but a complete rebuild.
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Not meaning to argue with you, but I'm not so sure it's as dire as you say.

Mary's car has 180,000 miles currently. It's had 2 sets of axles, the first due to the "soft axle" issue, and the second due to my error in doing the first set myself...I don't think I cleaned out all the debris properly. But the clutches are still fine...and I'm pretty sure the guy who did the second set didn't do anything to the centre chunk other than replace the bearings.

Also, there are a bazillion ex-copcar taxis running around with huge mileage that haven't had a complete rebuild. An acquaintance owns a taxi company and I'm friends with his mechanic.
 
RF Overlord said:
Not meaning to argue with you, but I'm not so sure it's as dire as you say.

Mary's car has 180,000 miles currently. It's had 2 sets of axles, the first due to the "soft axle" issue, and the second due to my error in doing the first set myself...I don't think I cleaned out all the debris properly. But the clutches are still fine...and I'm pretty sure the guy who did the second set didn't do anything to the centre chunk other than replace the bearings.
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As with many things, your mileage may vary. If you did the bearings on the carrier (pinion bearing and seal also?) that does constitute a complete rebuild minus the clutches. And the clutches, while less effective, aren't critical to the axle rolling down the road. Speaking of clutches, put a new set in there and drive it around a bit. Then let me know what you think.
 
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