NOTE: In the next Step, the muffler, tailpipe, and underbody shields must be removed before removing
the rear driveshaft. In addition, it is not necessary to remove the exhaust flexible pipe.
17. Remove the rear driveshaft. Follow the WSM procedures in Section 205-01.
• 100-001 (T50T-100-A) - Slide Hammer
• 205-832 - Remover, Halfshaft
18. Disconnect and position the axle assembly vent hose aside. See Figure 10.

23471J

FIGURE 10

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CPR © 2024 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2024

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TECHNICAL INSTRUCTIONS
PAGE 8 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

19. Using a flameless heat tool, such as the Rotunda Mini-Ductor II (part number IDIMD-700) or
equivalent, heat up both front rear axle housing support bolts, as shown in Figure 11. Using a breaker
bar, loosen both bolts. Then remove and discard both rear axle housing support bolts. See Figure 12.
• Torque: 129 lb.ft (175 Nm).
NOTE: The use of this tool is only to be used on the front RDU axle bolts.
REAR AXLE HOUSING
SUPPORT BOLTS

MINI-DUCTOR TOOL HEATING COIL

MINI-DUCTOR II TOOL
23471T

FIGURE 11

x2

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FIGURE 12
CPR © 2024 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2024

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TECHNICAL INSTRUCTIONS
PAGE 9 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

20. Remove and discard the rear axle housing support rear bolt. See Figure 13.
• Follow the Torque sequence below:

Stage 1: Torque to: 74 lb.ft (100 Nm).

Stage 2: Tighten an additional: 100° (degrees).

23471L

FIGURE 13
21. Gently lower down the transmission jack and remove the rear axle assembly. See Figure 14.
Use the General Equipment: Transmission Jack.
NOTE: Slowly lower the rear axle assembly while positioning it as you are removing the RH halfshaft
from the rear axle assembly.

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23471M

FIGURE 14

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CPR © 2024 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2024

TECHNICAL INSTRUCTIONS
PAGE 10 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

22. Install only a new differential housing cover (Do Not install the rear axle assembly at this time). Follow
the WSM procedures in Section 205-02.
23. Using an 11/16 in. (18 mm) or larger drill bit, drill out the rear axle assembly subframe bushing bolt
hole. See Figure 15. Click on the video link to see the drilling process:
NOTE: The use of a corded, high power drill and a good quality/sharp drill bit along with the use of
cutting oil will aid in drilling out the rear axle assembly subframe bushing bolt hole.
FRONT OF
VEHICLE

REAR AXLE ASSEMBLY
SUBFRAME BUSHING

11/16 IN. (18 MM)
DRILL BIT

23471P

FIGURE 15
NOTE: Refer to the Essential Special Service Tool (ESST) - Proper Inspection and Usage document, for
recommended lubricant and proper use and orientation of the components within ESST 204-594.
NOTE: It is not recommended to use a smaller threaded rod as it could fail under the forces/load required.
NOTE: The use of longer wrenches will aid in the removal and installation of the rear axle assembly
subframe bushing.

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07/2024

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TECHNICAL INSTRUCTIONS
PAGE 11 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

24. Using the ESST tools listed below, press out the rear axle assembly subframe bushing.
See Figure 16. Click on the video link to see the bushing removal process:
• 204-594 - Forcing Screw
• 204-356/1 - Remover/Installer, Radius Arm Axle Bushing
• 204-356/2 - Remover/Installer, Radius Arm Axle Bushing
• 307-739 - Installer, R3 Bearing
• 205-153 - Adapter, (Handle) for the 303-224 Installer
NOTE: The bearing, 307-739 Installer, R3 Bearing and 204-356/2 Remover/Installer, Radius Arm Axle
Bushing go towards the front of the vehicle.
NOTE: The rear axle assembly subframe bushing will be pressed out towards the rear of the vehicle.
FRONT OF
VEHICLE

204-594

307-739

BEARING

204-356/1

204-356/2

23471Q

FIGURE 16

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07/2024

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TECHNICAL INSTRUCTIONS
PAGE 12 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

NOTE: Make sure the tabs on the new rear axle assembly subframe bushing are horizontal with the
subframe. See Figure 17.
FRONT OF
VEHICLE

SILVER METAL SLEEVE
ON THE BUSHING
INSTALLED FLUSH
WITH THE REAR SUBFRAME

REAR AXLE ASSEMBLY
SUBFRAME BUSHING

23471R

FIGURE 17
25. Using the ESST tools listed below, install the new rear axle assembly subframe bushing.
See Figures 17 and 18.
• 204-594 - Forcing Screw
• 204-362/3 - Remover/Installer, Front Subframe Bushing
• 307-819 - Cup, Receiver
NOTE: The bearing and 307-819 Cup, Receiver, go towards the front of the vehicle.
NOTE: The new rear axle assembly subframe bushing will be pressed in from the rear of the vehicle.
FRONT OF
VEHICLE

204-594

307-819

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204-362/3
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BEARING

23471S

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FIGURE 18

CPR © 2024 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2024

TECHNICAL INSTRUCTIONS
PAGE 13 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

26. Replace both rear halfshaft seals. Follow the WSM procedures in Section 205-02.
- Use ESST 205-153, Handle and 307-758 Installer, Axle Seal.
NOTE: In the next Step, make sure both rear halfshaft circlip openings are located at the bottom or
6 o'clock position to allow for easy installation when directed to install them.
27. Remove and discard both rear inner halfshaft circlips. Then, install new circlips onto both rear inner
halfshafts. See Figure 19. Then, proceed to the next Step.
REPLACE BOTH REAR
INNER HALFSHAFT
CIRCLIPS

23471U

FIGURE 19
28. Reverse the removal steps, outlined in this procedure, to reinstall the rear differential housing
assembly.

E303259

29. Using a jack stand set the ride height before torquing any suspension bolts.
30. Install the LH rear wheel and tire. Follow the WSM procedures in Section 204-04A.
31. Check and top off the rear differential fluid. Follow the WSM procedures in Section 205-02.
IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are
under safety, compliance, or emissions recall. Unless a part is requested to
be returned to Ford, all parts replaced under this FSA must be scrapped in
accordance with all applicable local, state and federal environmental
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protection and hazardous material regulations. Refer to the Parts Retention,
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Return, & Scrapping section of the FSA dealer bulletin for further information.
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DEARBORN, MICHIGAN 48121
07/2024

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TECHNICAL INSTRUCTIONS
PAGE 14 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

PHOTO REQUEST SUBMISSION (SSSC PHOTO SUBMISSION)
Ford has requested photo evidence prior to performing the repair for the FSA.
The SSSC must provide approval prior to performing the repair.
1. Contact the SSSC and upload the necessary photos or copy of documentation(s) as an attachment
for review.
• Submit photos of the broken or missing RDU axle bolt.
• Include a picture of the VIN plate, a picture of the current vehicle odometer mileage and a picture
of the broken or missing rear axle bolt.
• The SSSC must provide an approval code, prior to performing any repairs.
2. There are two ways to submit the requested items to SSSC.
a. Directly in the SSSC contact request form while submitting your contact on your desktop.
b. Via PTS Mobile under the Images/Files Upload menu selection. Select SSSC in the sub-menu
and ensure your P&A code is correct. Upload the item(s) by selecting the appropriate FSA with
the option to use a prior contact ID. The item(s) will be associated with your SSSC contact
during submission.
NOTE: If you have not submitted an SSSC contact yet, then you can still upload the item(s) via PTS
mobile, and the item(s) will be available when opening your SSSC contact for this VIN and recall.
3. (If SSSC approval code is required) Upon approval, the SSSC will provide an approval code that must
be used for claiming.

CPR © 2024 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
07/2024

TECHNICAL INSTRUCTIONS
PAGE 15 OF 15
CUSTOMER SATISFACTION PROGRAM 24N01

Photo Requirement Examples
Acceptable Photos: Clearly shows the area of damage or failure related to this recall.
ACCEPTABLE
PHOTO

Photo shows proper lighting and clearly shows
cracking of the catalytic converter.

20212L

FIGURE 20
Unacceptable Photos: Is not clear or does not show the area of damage or failure related to this recall.
UNACCEPTABLE
PHOTO

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FOR
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07/2024

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Mobile Service Repair Assessment
Page 1 of 2
Customer Satisfaction Program 24N01
Certain 2020-2022 Model Year Explorer Vehicles
Rear Axle Bolt Fractures
Mobile Service Repair Assessment
Assessment levels have been identified to help determine the ease of performing eligible mobile
service repairs for a Field Service Action (FSA) outside of the dealership service facility.
Dealer Bulletin
Within the Administrative Information Attachment of the dealer bulletin a mobile service repair
assessment level(s) will be provided. These assessment levels have been determined using the
amount of time, equipment and labor identified to perform the intended service action.
Assessment Levels
- Mobile Reprogramming
- Light Mobile Service
- Enhanced Mobile Service
- Advanced Mobile Service
- Wheel and Tire Mobile Service
- Not a Mobile Service Repair
Description of each level that is used to determine the overall assessment.
– Mobile Reprogramming
• Module Programming or similar type services
• Minimum tools maybe required other than an IDS/FDRS setup
• FDRS programming that requires internet connection (wi-fi or mobile hotspot)
• Make sure vehicle has a charge port to ensure battery voltage is maintained during
flashing of the module(s)
• Repairs not greater than 1 hour in length (including time to wait for programming)
Note: The location will need a charging station or wall box to maintain the 12-volt battery.
•
•
•
•

– Light Mobile Service
Interior repair procedures that do not require seat, dash, or headliner removal
Under hood repairs that do not require large component removal
Exterior repairs that do not require large component/panel removal
Repairs may require standard hand tools (Access to a Technician starter kit or similar)

 Copyright 2024 Ford Motor Company

Mobile Service Repair Assessment
Page 2 of 2
Customer Satisfaction Program 24N01
Certain 2020-2022 Model Year Explorer Vehicles
Rear Axle Bolt Fractures
– Enhanced Mobile Service
A two-person process is required anytime a procedure requires work under the
vehicle
• Brake Inspection and Brake Repair/Replacement
• Limited Suspension Component replacement (no alignment)
• Under Vehicle access for limited repairs (no large component removal)
• Vehicle Check Up - VCU
• Pre-Delivery Inspection - PDI
• Used Car Inspection/Presale Inspection
• May require floor jack, jack stands, and impact tools
Note: Wheel lock may be required.
•

•
•
•

– Advanced Mobile Service
Fluid Exchange/Oil Change
Light Repairs
Brake Hydraulic Repairs

– Wheel and Tire Mobile Service
• Tire Removal from Wheel
• Tire Balancing
• Tire Repair
Note: Specialized Mobile Service unit and equipment including Tire balancer and Tire
Changer required.
– Not a Mobile Service Repair
• Large component removal
• BEV Battery Replacement
• Requires a vehicle hoist – to complete the repair (more than inspection)
• Required vehicle alignment
• Requires significant vehicle disassembly
• Repairs greater than 2-3 hours
• Any repairs that require M-Time
• Includes a service procedure where the vehicle owner may be distressed about the state
of their vehicle

 Copyright 2024 Ford Motor Company

Mobile or Pick-Up and Delivery Repair Record
Page 1 of 1
Customer Satisfaction Program 24N01

Vehicle Pick-Up and Delivery Record
VIN ____________________________ received (check one):
☐ Pick-up and/or delivery service

As outlined below for the 24N01 Field Service Action program.
☐ Pick-up

– Date: _______________

☐ Delivery

– Date: _______________

Repair Order #

Repair Order Date

Service Manager Signature

Date