Transfer Case Problems of Ford Expedition

Ford Expedition owners have reported 19 problems related to transfer case (under the power train category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford Expedition based on all problems reported for the Expedition.

car image   Transfer Case problem of the 2011 Ford Expedition 1
Failure Date: 01/27/2015

The contact owns a 2011 Ford Expedition. While attempting to accelerate on an incline, the vehicle decelerated and the front wheels failed to turn. The 4x4 system also independently activated. The vehicle was taken to the dealer, who discovered that the 4x4 motor and solenoid failed and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failures. The failure mileage was 65,000.

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car image   Transfer Case problem of the 2002 Ford Expedition 2
Failure Date: 12/01/2012

Rear differential control links rusted thru and broke. This allowed the differential to move toward the rear. When it moved far enough the rear drive shaft fell out of the transfer case and broke off at the rear yoke. Considering the number of Expeditions and navigators on the road. . . Someone is going to get killed.

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car image   Transfer Case problem of the 2001 Ford Expedition 3
Failure Date: 01/05/2008

Within months of purchasing the vehicle it began to spontaneously go into 4 wheel drive. Initially I thought I had hit the switch which is nowhere near the steering wheel. I put the vehicle in neutral and then back into drive and it seemed fine. It began happening more and more frequently. On one occasion in 2003 I was driving on the freeway and it locked up. It went into 4 wheel drive and luckily I was wearing my seatbelt because the force was comparable to slamming on my brakes. I drove off the freeway and was able to get it out of 4 wheel drive but was terrified to drive on the freeway. I called the dealership who told me they couldn't look at it until the following morning. Reluctantly I drove it home. I was repeatedly told nothing was wrong with my vehicle while it was under warranty. While driving my vehicle through a parking lot it decided to go into 4 wheel drive and completely locked up. I could not drive in forward or reverse. I had the vehicle towed to a dealership who told me that there was problem with the 4 wheel drive that could be fixed but that my warranty did not cover it. About a thousand dollars later I drove off with my vehicle believing that it would work properly. Within less than one year of the repair I was on the freeway again and my 4 wheel drive kicked in. Once again saved by the seatbelt, I called the dealership. Again I was told that the repairs were only covered for 1 year or a certain amount of miles (not sure on the miles ?5000). The dealership told me that this was not an unknown problem that Ford was having. They told me that they were aware of the problems but all they could do was keep fixing it. The dealership even had the nerve to tell me that when it starts to bind up to put the vehicle into reverse. Very helpful when your doing 65 on the freeway. Today while actually using my 4 wheel drive the transmission continually slipped.

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car image   Transfer Case problem of the 2005 Ford Expedition 4
Failure Date: 12/01/2007

The contact owns a 2005 Ford Expedition. While driving 5 mph, the vehicle slid into a ditch. The rear driver's side lights and bumper were damaged. The dealer stated that the vehicle was supposed to come equipped with four wheel drive, but did not. The manufacturer paid to install the four wheel drive feature in December of 2006. On December 1, 2007, the vehicle slid out of the driveway into the middle of the street. In January of 2008, the vehicle was taken to the dealer and they reinstalled the four wheel drive. The contact retrieved the vehicle on January 10, 2008 and the four wheel drive failed again seven days later. The current mileage was 33,900 and failure mileage was 12,000. Updated 3/4/08 the dealer has since fixed the 4-wheel drive.

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car image   Transfer Case problem of the 2001 Ford Expedition 5
Failure Date: 08/11/2007

The contact owns a 2001 Ford Expedition. The contact heard an unfamiliar noise while driving the vehicle. He took the vehicle to the dealer and was informed that the transfer case needed to be replaced. The dealer made the repair, but three days later the vehicle failed to drive in reverse. The contact returned to the dealer and was informed that the transmission needed to be replaced. The speed was unknown. The current mileage was 105,000 and failure mileage was 58,000.

car image   Transfer Case problem of the 1999 Ford Expedition 6
Failure Date: 04/12/2006

When the car is hot it automatically shifts into 4 wheel drive. Ford is aware of the problem and sent an advisory to dealership shops. They advised this is problem and must replace the 4 wheel drive motor which is at a cost of 525. 00. Then and only then if that doesn't fix it you have to replace 2 other switches which then costs an additional 600-800. 00. I would like to find out why this is not considered a recall by Ford since this is a very dangerous issue should the 4 wheel drive kick in while driving on the highway the wheels would lock up and all people in the car would be killed. I have file a complaint with Ford and they advised there is nothing they can do about it since the car is a 1999. According to our Ford dealership this can happen in 1999 through 2002 Ford Expeditions, explorers and excursions as well as there f series trucks.

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car image   Transfer Case problem of the 2001 Ford Expedition 7
Failure Date: 03/24/2006

: the contact stated the vehicle shifts into four wheel drive low on its own. The vehicle has been to the dealership for repairs. The transfer case pump and gem module was replaced, neither of these repairs fixed the problem. This problem caused an accident, while traveling 40 mph in a turn, the vehicle shifted in 4wd low and the vehicle lurched to the right. The vehicle hit a rock wall on the front passenger side. There was a police report taken at the scene and both occupants received minor injuries. The vehicle was towed to an independent repair shop for repairs.

car image   Transfer Case problem of the 1998 Ford Expedition 8
Failure Date: 01/01/2006

1998 Expedition cruise control was disconnected. When it was reconnected there was a sudden vibration. The consumer was informed of a recall on the cruise control in September 2005 and had it disconnected while waiting to have it fixed. On December 28, 2005 the cruise control was reconnected but wasn't use until January 2006. When it was finally used there was a vibration. The vehicle was parked and the consumer observed fluid leaking onto the driveway. The vehicle was taken to the dealer who stated that there was no was that the vibration was connected to the recall work. The vehicle was taken to the consumer's regular mechanic who determined that the transfer case bushing was damaged along with the driveline and transfer case. All parts had to be replaced.

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car image   Transfer Case problem of the 1998 Ford Expedition 9
Failure Date: 06/27/2004

We were on vacation June 27, 2004 and our 1998 Ford Expedition broke down 15 miles outside of flagstaff, az. We were towed to aamco transmissions, whom after getting authorization from our service contract to check our truck found that a seal gasket in our transfer case had melted and all the oil ran out. These are supposed to be covered for 150,000 miles, our truck is at 92,184 miles. I have a service contract covering me for 96,000 miles. They refused to fix it because they said it was tampered with first, then they said the transmission wasn't covered, then it was because we drove it with no oil. Aamco told them us the part was covered under our service contract but that they get this alot from service contracts where they don't want to pay for the work. Aamco also said that these trucks do not have indicators on the transfer cases to show that anything is going wrong or that oil is leaking. We have never had problems. Our r oil levels were checked on June 25th before taking off for vacation and everything was fine. We have never had leaks. We had 3 of ouryoung grandchildren with us. We were driving on a freeway and our truck just started slowing down really fast and were lucky there were not many cars at that time so we could pull off the side of the freeway. So you can see that this thing could lead to accidents if someone is driving and all of a sudden your vehicle slows down in heavy, fast traffic because you have no way of knowing this is happening or anything is happening with your truck. We are having this fixed at our expense, seal gasket in the transfer case?, $1700 + $240 labor to check it and take it apart. I will never buy another service contract after this on a used vehicle. I bought my truck from chapman Chevrolet who since changed their name to freeway Chevrolet in chandler, az and they were not willing to help me with this service contract which I bought from them.

car image   Transfer Case problem of the 2001 Ford Expedition 10
Failure Date: 05/01/2004

I have a 2001 Ford expidition with only 35000 miles on it and the transmission burned up. The repair shop said the transmission problem was common with the expidition and it was flawed in its design. It cost me $2,200 to overhall the transmission, I asked Ford to cover the repair, they said no, please help, thanks, mark.

car image   Transfer Case problem of the 1997 Ford Expedition 11
Failure Date: 09/07/2003

While driving 4-wheel drive engaged without warning.

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car image   Transfer Case problem of the 2000 Ford Expedition 12
Failure Date: 08/29/2003

When making a left hand turn at various speeds transfer case (4 wheel drive) would engage without warning. Cause has yet to be determined.

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car image   Transfer Case problem of the 2000 Ford Expedition 13
Failure Date: 06/16/2003

Drivetrain, had repaired but still has the same problem here and there.

car image   Transfer Case problem of the 1999 Ford Expedition 14
Failure Date: 03/17/2003

4wheel drive engages sporadically while driving. Dealer notified(nothing they can do?) must stop , disengage transmission ,and cycle transfer case to clear. Please advise if there is a known recall and/or repair procedure. Any infomation would be appreciated-thank you -jao.

car image   Transfer Case problem of the 1999 Ford Expedition 15
Failure Date: 10/02/2002

While driving the vehicle the four wheel drive mechanisms engage on and off. Dealer has been notified (nothing they can do) please provide further information. Ts.

car image   Transfer Case problem of the 1997 Ford Expedition 16
Failure Date: 09/30/2002

Consumer states that the vehicle locked up on four wheel drive, which results in the vehicle not driving at faster then 10-15 mph. Contacted dealer.

car image   Transfer Case problem of the 1998 Ford Expedition 17
Failure Date: 06/13/2001

While operating the vehicle at about 20 mph, it droped into 4 wheel low range completely on its own. The dash switch was still in 2 wheel drive. The transmission began screaming and grinding gears and would not come out of 4 wheel low. Vehicle was towed to Ford dealership where they found nothing wrong. After reporting these NHTSA complaints and service bulletins about this very same problem, and providing the service manager with copies, they suddenly found the problem. They are replacing all the components including "mode switch" gem module, 4x4 shift motor. They'll also check all connections, change all fluids including transfer case and transmission. We've been assured this will resolve the situation. We'll submit a follow-up report if problem recurs.

car image   Transfer Case problem of the 1998 Ford Expedition 18
Failure Date: 11/28/2000

Shortly after purchase transmission leaked , had to be repaired. Currently, transmission squealed. Took vehicle to dealer, who found a leak. Also, transmission was tearing itself up, and had to be replaced. Transfer case broke and drive shaft was shuddered. Steering was very loose due to lower steering shaft failure.

car image   Transfer Case problem of the 1999 Ford Expedition 19
Failure Date: 06/20/1999

1) upon accelerating from a stop, the transmission/transfer case seems to slip and shudder as if the tires are not grabbing the road. This is at all speeds, whether slow or quick starts. Also, during high speed acceleration such as when passing on the highway, there is a low pitch growling sound and vibration as if the engine mounts are broken. 2) the front intermittent wipers turn on by themself occasionally, usually just for one sweep then turn back off. 3) the rear automatic load leveling air shocks on one occasion deflated totally after being parked for about 4 hours. The truck chassis was nearly touching the rear tires, I was unable to drive away until they reinflated after starting the vehicle.

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