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Transfer Case Problems of Ford Explorer - part 1



Ford Explorer owners have reported 72 problems related to transfer case (under the power train category).

car image   Transfer Case problem of the 2003 Ford Explorer 1
Failure Date: 07/27/2014

I have had three incidents with my 2003 Ford Explorer. The first incident involved the suspension ( sway bars snapped, tires had to be repaired). Second incident was the transfer case and a wiggling drive shaft along with rear wheel bearings ( parts deemed defective by mechanics) , and emergency brakes that snapped off in my mechanics hands because they were rusty. Now it is transmission work for a possible faulty sensor. Ford needs to recalls before someone is killed due to catasrophic equipment failure! ive called them every time and they are aware of the issues but refuse to do anything other then document them and say have a nice day!.

See all problems of the 2003 Ford Explorer.

car image   Transfer Case problem of the 2007 Ford Explorer 2
Failure Date: 03/25/2014

In 9/2013 the vehicle was taken to the dealership for a metallic sound that occurred while it was turning or coasting. Diagnosis was that the 4x4 module was commanding the transfer case to engage when not commanded. The dealership received an improperly recommended module from Ford. They ended up using a sport trac module. This stopped the noise but caused the traction light to come on. We were advised to replace the anti-lock brake module. In 2/2014 we replaced the anti-lock brake module. On 3/25/2014 the transmission lost reverse and first gear and needs to be replaced. Ford will not admit the wrong part was used and caused the transmission to go.

See all problems of the 2007 Ford Explorer.

car image   Transfer Case problem of the 1997 Ford Explorer 3
Failure Date: 07/11/2013

This letter is intended to address ineffective service by aamco that led to failure of a transmission in my vehicle. As you see by the attached letter, I voiced concern about this last year and all aamco suggested was to take it back to the dealer that performed the ineffective service. I requested the right to take the vehicle to another aamco center, but your response was to take it to the center that I already had doubts about. Let me set the scenario again. ?with initial grinding sounds and lack of reverse, I took to clinton transmissions in 2011 and they informed me the transmission needed to be rebuilt. The vehicle was parked until 2012. ?in 2012, I called the waldorf aamco center and they informed me it may not be the transmission and to let them look at it. It was towed in and I was informed that the transmission was fine but the transfer case was bad. ?all totaled, I paid $1534. 76 for transfer case, $430. 03 for parts, and $600 for labor. This does not include the other services that the center said I needed. ?the vehicle was taken back twice for an od light that came on as soon as I left the center. They seemed unable to diagnose the problem. ?I felt concern for the period I was driving and wrote corporate to request assistance. ?earlier this year while driving to south carolina, the grinding sound started again and reverse went out. I notified corporate and the waldorf center and was told to go to the nearest aamco. ?I went to the columbia, south carolina aamco and after diagnostic, told me the same thing that the clinton transmission told me in 2011. The transmission had internal damage and needed to be rebuilt. ?I left the vehicle in columbia and had to purchase a new vehicle. With these facts in mind, aamco can surely see where ineffective service led to a safety failure.

See all problems of the 1997 Ford Explorer.

car image   Transfer Case problem of the 2004 Ford Explorer 4
Failure Date: 07/27/2012

Driving, and and light came on, 4x4 light blinking 5times every 2/3 miles. Went to reverse and got a hard jerk. Car started making a rubbing noise. Took ithe shop was told it was either the transmission or the transfer case.

See all problems of the 2004 Ford Explorer.

car image   Transfer Case problem of the 2002 Ford Explorer 5
Failure Date: 04/05/2012

Transmission failure - stupid design doesn't allow you to check fluid level, leak at transfer case seal seems to have caused loss of fluid and cannot be added without some special pump to fill transmission back up because it's a sealed unit. Designed so only Ford dealers can do service and then it just goes out and you're driving 65 mph down the mountain and unable to control speed. Ford needs to recall these piece of crap transmissions yet won't even acknowledge there's a problem although every dealer & tranny mechanic knows of the issues.

See all problems of the 2002 Ford Explorer.

car image   Transfer Case problem of the 2003 Ford Explorer 6
Failure Date: 07/07/2011

Suddenly the transfer case started jerking and the SUV was shaking badly that I almost couldn't drive it home. I was lucky to have this happening at 1/2 mile from my house and at about 20-25 miles per hour! it was no code to indicate where the failure occured within the power train. I tooke a part the rear end, I found nothing wrong with it. I started to troubleshoot the transfer case and I noticed that the electrical motor with actuator does not spin the shaft from tranfer case, reason that the transfer case can't select firmly the position of hi, low por 4wd!!!!. Observing that trhe motor of the transfer case sifter does not spin, I purchesd a new motor from Ford,. After replacemnt, the problem persisted; so, I replaced the transfer case module, behaind the glove box; no result. To be able to move the car around I unplugged the transfer case motor shift frokm the main harness and the SUV stays now in 4wd with blinking lights on my dash for abs and 4x4 wd!!! I am still wandering what could happend to me if the jumping and grinding was to happend when I was driving the car with 65-70 miles per hour and the power train could snap and the drivesfat could fly out. . . Who shall be resonsible for my life or somebody else's that I could hit? I consider that the manufacturer shall recall the Explorer's affected and address the transfer case issues. The old parts that I have replaced are available, they are functgional. I still don't know what is wrong becasue I couldn't find any advise from any Ford sites\, neither from a qualified diagnostic specialist. If I go to Ford dealership they will be charging tons of $$$ until the car runs again; they don't care how many parts will replace and I will have to pay Ford's mistakes from my pocket; this is not right!.


car image   Transfer Case problem of the 1997 Ford Explorer 7
Failure Date: 02/24/2011

We maintained our vehicles regularly, after replacing the transfer case not 8 months ago now the transmission went out. Spent $2400 for a rebuild. Shop states this model is a piece of *, and the have made a lot of money from Fords poor engineering on this model.

car image   Transfer Case problem of the 1997 Ford Explorer 8
Failure Date: 10/07/2010

After turning a corner at less than 15 mph a loud sound was heard and the engine raced but stopped moving. Tried all gears and after having it towed to a repair facility I was informed that the transfer case broke. I had to have it replaced.

car image   Transfer Case problem of the 2002 Ford Explorer 9
Failure Date: 11/07/2009

2002 Ford Explorer XLT 4 wheel drive does not actuate anymore. Mechanic says it is a defective 4x4 control module. Seems to be a common problem with Ford. Safety issue when expecting traction in winter and not having it.

car image   Transfer Case problem of the 2002 Ford Explorer 10
Failure Date: 04/18/2009

2002 Explorer, 1st incident, had od light flashing w/very hard shift. Had transmission rebuilt. About 6 months later, slipping at 30 to 40 miles per hour, had transfer case rebuilt. 6 weeks later transmission slipping again at 30 to 40 mph with loud whine when stopping.


 
car image   Transfer Case problem of the 2002 Ford Explorer 11
Failure Date: 03/13/2009

I have an issue with my transmission in my 2002 Ford Explorer. The car has 76,000 miles and the o/d light flashes and 2nd gear is a mess. It started out of no where. . Read more...

car image   Transfer Case problem of the 2002 Ford Explorer 12
Failure Date: 01/05/2009

2002 Ford Explorer transmission flew into 4x4 low automatic while driving at 50 mph. The 4x4 module part had been replaced once already,and is the culprit of throwing it into an unsafe position. The issue keeps coming up, and the dealer has had no responsibility for replacing the "known Ford problem" in over 7 years. This issue is expensive to repair, but the problem is the safety of the vehicle and the passengers at higher speeds. It can cause the vehicle to first slow down by the physical limitations of the transfer case, and cause the vehicle to be out of control and flip. It's so present on the internet now, I wonder why no one has gotten Ford to face the issue, even the dealers know, but get no response back from parent Ford. The vehicle mentioned is well cared for, as well as only in the low 80,000 mile area presently. This happened around 38,000, 43,000, 58,000, 63,000, and now at 84,000. Even the dealer agrees that the 4 wheel auto feature, (which is the idle state of the transaxle) cannot be started when the vehicle is fired up. This causes numerous issues with other components reliable to the module. The module, is built by motorola and I've been advised that the any new owner of an Explorer in the date range should have it replaced or inspected due to it not being able to handle typical surge spikes from the vehicles power systems. The replacements should have it. But that doesn't help with the advise if it already occurs. Which it has been. Now I've got a $45,000 paperweight in my driveway again. Corrections are made, but results are always the same. Ford needs to address the issue publicly before others are in accidents or fatalities occur.

car image   Transfer Case problem of the 1996 Ford Explorer 13
Failure Date: 10/01/2008

4x4 fails to activate leaving vehicle impaired in 2 wheel mode during critical driving times. Switch on dash goes out, appears to be failure of 4x4 control module and transfer motor. Problem occurs after battery has been disconnected. Repair for vehicle requires changing out control module or transfer case motor. Problem appears to occur in all models of Ford Explorer 1991 - to date.

See all problems of the 1996 Ford Explorer.

car image   Transfer Case problem of the 2002 Ford Explorer 14
Failure Date: 07/23/2008

While driving my 02 Ford Explorer XLT I noticed the o/d light would come on and it would be hard to shift. The was a rattling noise coming from transfer case which had a brownish fluid leaking from it. Went to dealer and was told the transmission had to be replaced.

car image   Transfer Case problem of the 2002 Ford Explorer 15
Failure Date: 04/05/2008

I bought my Explorer used with 67000 miles on it I had it checked out by a mechanic before I bought it but he didn't do a very thorough job. After about 3 weeks I had a hard time putting into reverse but then slammed into gear and I did not happen again for awhile this lasted on and off for a year and half when one day it wouldn't go into reverse at all and no other gears either I had it repaired and they said it was the transfer case then my 4 wheel drive light flashed and stopped working that was something electrical , 1st , 2nd and reverse gears started slipping I had those repaired now my overdrive light flashes on and off and I have been told it is definitely my transmission and probably always has been. I know someone else having this problem with their 02 Ford and speaking to the mechanics they were not surprised at all and it seems as though lots of 02 Ford Explorer owners on line are having the same or similar problems. How many vehicles does it take to turn into a recall???.

car image   Transfer Case problem of the 2006 Ford Explorer 16
Failure Date: 03/05/2008

I bought a 2006 Ford XLT Explorer with apx. 17,000 miles. I had it for about 3 months it had about 19,000 miles. I drive it about 100 miles to a convention and by the time I got there and pulled into a parking lot the vehicle started shifting hard, jerking and lunging. It was making a loud banging sound and felt like the transmission was going to fall out. I took it to Ford, they did some work on the transfer case and replaced a module. About a month and a thousand miles later, it started doing it again. Took it back to Ford and they did some more work. The shifter lever was replaced. Later it started doing it again. I have taken it back several times and the vehicle continues to have the problem. It doesn't do it every day but does do it several times a week, some days are worse than others. As time goes by it seems to get worse and happen more often. Sometime when I put the vehicle in reverse there is a delay to engage and one morning it cause me to back into another vehicle. It also has a cracked running board.

See all problems of the 2006 Ford Explorer.

car image   Transfer Case problem of the 2003 Ford Explorer 17
Failure Date: 01/30/2008

The transfer case failed on our 2003 Ford Explorer. This is a known problem at Ford and due to a design flaw with the Explorer. It cost $2,000 to fix. Our mechanic referred us to a transmission/transfer case specialist who had seen multiple Explorers with this problem. Ford should issue a recall for this known defect. The consequences of a failure in the transfer case can be a complete shredding of the gears and sudden loss of power, which could be extremely dangerous.

car image   Transfer Case problem of the 2002 Ford Explorer 18
Failure Date: 06/01/2007

I have an 2002 Ford Explorer and it only has 81,000 miles and I have had problems with the transmission since it hit 77,000 miles. It has been in shop, a transmission specialist, at least 10 times for the same problem. I have had the entire transmission overhauled and the same parts keep wearing down. This is causing the tranny to slip and slam into gear. I am now taking it back into the shop after 6 months. Ford needs to do something to help the american people if they still want us to buy american.

car image   Transfer Case problem of the 2003 Ford Explorer 19
Failure Date: 05/11/2007

The contact owns a 2003 Ford Explorer. The contact stated that she heard a clicking sound during deceleration. A mechanic diagnosed the cause of failure as a worn out range hub in the transfer case. The contact stated that she could never get out of 4 wheel drive, which burns more gas and activates components that are unnecessary during normal driving. The current mileage is 73,000 and failure mileage was 70,000. Updated 02-01-08.

car image   Transfer Case problem of the 2006 Ford Explorer 20
Failure Date: 10/14/2006

At sharp turns either to the left of the the right, the auto 4x4 enagages and you feel a large shutter. I was fixed by the dealer(they reprogramed the 4x4 permiters) 4 months later if has came back. Nothing has seemed to fix it, many similar situations like mine on the internet.

car image   Transfer Case problem of the 2002 Ford Explorer 21
Failure Date: 08/31/2006

: the contact stated when the vehicle was started it would be in 4-wheel drive high. Sometimes when the vehicle was backed up and/or making right or left turns the vehicle would go into 4-wheel drive high on its own. While driving at various speeds the vehicle kicked into 4-wheel drive high on its own. The dealership has not been contacted but the contact plans to call them soon. The 4x4 high light illuminated each time.

car image   Transfer Case problem of the 2002 Ford Explorer 22
Failure Date: 08/16/2006

: the contact stated the transmission slipped at variable speeds, sometimes not engaging the next higher gear or at times the engine would race, then slam into gear with a banging noise. The vehicle was taken to a service dealer where computer diagnostics would not recognize the 5th gear in the automatic transmission. The transfer case was rebuilt, but the problem continued. The vehicle has been inspected on 7 occasions. The rear lift gate window hinge was replaced, but continued to fall out of the hinge. The manufacturer was notified.

car image   Transfer Case problem of the 2002 Ford Explorer 23
Failure Date: 07/12/2006

My 2002 Ford Explorer with only 40,000 original miles was making noise when it was going up a hill or during acceleration. Since it was no longer under warranty I took it to a transmission repair shop. It needed the transfer case to be replaced which cost me over $1600.

car image   Transfer Case problem of the 2002 Ford Explorer 24
Failure Date: 07/08/2006

Transfer case failure. Dealer-ted britt, fairfax, va refuses to cover under power train warranty.

car image   Transfer Case problem of the 2002 Ford Explorer 25
Failure Date: 06/01/2006

1. ) my 2002 Ford Explorer 4wd tends to surge in 1st,2nd, and 3rd gear. It feels as though there some slippage issues. 2. ) no "failure", yet. 3. ) nothing has been done to fix the issue yet.