Some 2011-2014 Ford F-150 trucks built on January 1, 2011, and through April 1, 2014, may exhibit an intermittent click or snap-type noise from the rear axle on initial light acceleration from a stop while in drive or reverse. The noise may also occur on light acceleration after changing direction from drive to reverse or reverse to drive.
If the noise is heard at the rear driveshaft universal joint, apply a few drops of Motorcraft penetrating and lock lubricant to each of the U-joint retaining clips, wipe off the excess and re-test. If the noise is still present, place the transmission in neutral and lift the vehicle on a hoist. Index-mark the driveshaft flange and pinion flange for correct alignment. Remove and discard the four driveshaft flange bolts. Disconnect the driveshaft centering socket yoke from the pinion flange. The yoke fits tightly on the pinion flange pilot. Pry in the area shown in the illustration to separate. Never hammer on the driveshaft or any of its components. Support and position the driveshaft aside.
Remove the rear disc brake calipers and support them out of the way to allow the axles to rotate freely. Rotate the rear axle pinion and record the turning torque with the differential and axle shafts installed. Remove the rear pinion flange, pinion seal and oil slinger. Press the pinion flange off following the workshop manual to prevent damage to the pinion flange.
Replace the oil slinger with a new slinger. Lubricate both side of the shim with Motorcraft Premium Long Life grease. Install the shim, pinion seal and pinion flange. Adjust the rear pinion preload to +/- 2 in-lb from the initial pinion turning torque previously recorded. Note that used bearings require a lower preload than new bearings. Install the brake calipers. Reinstall the driveshaft, aligning the matchmarks. Install four new driveshaft flange bolts and tighten to 76 ft-lb (if using used bolts, apply threadlocker to threads). Make sure that the driveshaft centering socket yoke seats squarely on the pinion flange and tighten the bolts evenly in a criss-cross pattern.
P/N PART
XL-1 ....................................Motorcraft penetrating/lock lube
TA-25-B...............................Motorcraft threadlock
BL3Z-4676-A....................... rear pinion seal
N800594-S100 ................... flange bolts (4)
FL3Z-7N357-A .................... oil slinger
XY-75W140-QL ............. Motorcraft 75W140 synthetic axle lube
XG-1-E1 ..............................Motorcraft premium long-life grease
Never hammer the flange to separate. Only pry in the area shown here.
