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Transmission Delayed Engagement OVERVIEW This bulletin involves replacing the front pump assembly in the transmission and checking the Transmission Control Module (TCM) for the latest software revision level. MODELS MODELS Year 2004 2002 – 2004 2003 2003 2002 2004 2002 2003 2002 2003 2002 2003 2002 2003 2003 Model Code (CS) (JR) (KJ) (KJ) (LH) (PL) (PT) (RG) (RS) (TJ) Model Pacifica Sebring Convertible/Sebring Sedan/Stratus Sedan Liberty Cherokee (International Markets) 300M/Concorde/Intrepid Neon PT Cruiser Chrysler Voyager (International Markets) Town & Country/Caravan/Voyager Wrangler SYMPTOM/CONDITION Vehicle operator may experience a delayed or temporary loss of transmission engagement after initial start up. The condition follows an extended soak (several hours) and may be accompanied by a harsh 4-3 downshift. Technician may find Diagnostic Trouble Code (DTC) P1791/P0944 – Loss of Prime. DIAGNOSIS Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes the Symptom/Condition or the technician finds DTC P1791 or P0944, perform the Repair Procedure.

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Removal 1. Raise and support vehicle on frame rails. Remove wheels. Index mark drive shaft and axle yoke for installation reference. Remove drive shaft. 2. Disconnect rear track bar at axle bracket. Remove axle vent tube at axle. Disconnect parking brake cables at equalizer (rear axle). Remove wheel speed sensors (if equipped). Disconnect shock absorbers from axle. Disconnect brake line at axle junction block. Disconnect stabilizer bar links from axle. 3. Support axle housing. Disconnect upper and lower control arms at axle. Lower and remove assembly to release coil spring pressure. Remove coil springs. Lower and remove axle housing assembly from vehicle. Installation Align spring mounting points, and place axle in position. To install, reverse removal procedure.

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Removal 1. Raise and support vehicle. Remove wheel, disc brake caliper, rotor, cotter pin, nut retainer, and axle hub nut. Remove hub-to-steering knuckle attaching bolts. Remove hub and rotor shield from steering knuckle. Remove axle shaft from axle tube. See the FRONT AXLE article in DRIVE AXLES. NOTE: DO NOT disconnect caliper unless service is needed. Support caliper with wire to prevent hose damage. 2. On models with front axle shift motor, remove outer axle shaft from right axle tube. Leave shift collar on intermediate shaft. On all models, remove caliper anchor plate from steering knuckle. Remove steering knuckle and ball joint cotter pins. Remove ball joint nuts. Strike steering knuckle at ball joint stud boss with a brass hammer to loosen knuckle from ball joint studs. Remove steering knuckle. See Fig. 2 . Installation 1. Position steering knuckle over ball joint studs and install nuts. Tighten nuts to specification. Install NEW cotter pins. Install caliper anchor plate and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install axle shafts into axle tubes. 2. On vehicles with front axle shift motor, ensure shift collar is correctly positioned on intermediate axle shaft, install axle into shift collar inside axle tube. Ensure axle shaft is completely engaged with shift collar. 3. On all models, apply bearing grease to spindle hub bore in steering knuckle and install rotor shield and hub. Tighten spindle hub bolts. Install hub washer and nut. Tighten hub nut to specification. Install hub nut retainer and install NEW cotter pin. Install rotor, caliper and wheel. Lower vehicle.

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FORD: 1997-2005 Expedition, F-150 2002-2005 Explorer LINCOLN: 1998-2005 Navigator 2003-2005 Aviator MERCURY: 2002-2005 Mountaineer This article supersedes TSB 05-12-6 to update the Service Kit and Service Procedure information. ISSUE Some vehicles may exhibit an axle whine or hum during acceleration, deceleration and/or cruise. ACTION An axle repair kit has been developed which incorporates most parts required for a comprehensive axle repair. The kit should be used instead of installing a complete axle assembly to repair an axle whine/hum. Replace Ring and Pinion with Axle Kit and Components. NOTE REFER TO THE “DIFFERENTIAL RING AND PINION” IN-VEHICLE REPAIR PROCEDURE IN THE ONLINE WORKSHOP MANUAL SECTION 205-00, FOR THE LATEST AXLE DIAGNOSIS AND REPAIR PROCEDURES. NOTE FOR 1999 AND PRIOR MODEL YEAR VEHICLES, USE THE 2000 MODEL YEAR WORKSHOP MANUAL.

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Axle Shaft Removal 1. NOTE: The wheels and tires do not have to be removed in order to remove the axle shafts. Loosen and remove the retaining bolts. 2. Remove the axle shaft. 3. Inspect the axle shaft O-ring seal for cracks, nicks or wear and replace it if required. Installation NOTE: Lubricate the O-ring seal with lubricant prior to installation of axle shaft. 1. Install the axle shaft. 2. NOTE: Coat the threads of the retaining bolts with stud and bearing mount. Install the retaining bolts and tighten.