Transfer Case Problems of Ford Explorer
Ford Explorer owners have reported 70 problems linked to transfer case (under the power train category).
#1 - Transfer Case problem of the 1997 Ford Explorer
The vehicle involved is a 1997 Ford Explorer. 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. This transfer case issue occurred Thu., Jul. 11, 2013.
See all problems of the 1997 Ford Explorer.
#2 - Transfer Case problem of the 1997 Ford Explorer
The vehicle was a 1997 Ford Explorer. The vehicle identification number (VIN) is 1FMDU34E2V_. 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. This issue happened on Thursday, February 24, 2011.
#3 - Transfer Case problem of the 1997 Ford Explorer
The vehicle involved is a 1997 Ford Explorer. 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. This issue happened on 10/07/10.
#4 - Transfer Case problem of the 2004 Ford Explorer
The car is a 2004 Ford Explorer. 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. It was Friday, Jul. 27, 2012 when this transfer case issue occurred.
See all problems of the 2004 Ford Explorer.
#5 - Transfer Case problem of the 2002 Ford Explorer
The vehicle was a 2002 Ford Explorer. 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. This issue happened on Thursday, Apr. 5, 2012.
See all problems of the 2002 Ford Explorer.
#6 - Transfer Case problem of the 2003 Ford Explorer
The vehicle involved is a 2003 Ford Explorer. 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!. This problem occurred on Thursday, July 7, 2011.
See all problems of the 2003 Ford Explorer.
#7 - Transfer Case problem of the 2006 Ford Explorer
The vehicle involved is a 2006 Ford Explorer. 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. This transfer case issue occurred Oct. 14, 2006.
See all problems of the 2006 Ford Explorer.
#8 - Transfer Case problem of the 2006 Ford Explorer
The vehicle was a 2006 Ford Explorer. VIN of the vehicle was 1FMEU73886_. 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. This transfer case issue occurred Wednesday, March 5, 2008.
#9 - Transfer Case problem of the 2004 Ford Explorer
The car is a 2004 Ford Explorer. While driving at any speed consumer was unable to control the vehicle, causing the driver to run off the road. Consumer was able to drive the vehicle to the dealership, and mechanic determined that the 4-wheel drive failed. This transfer case issue occurred Apr. 12, 2003.
#10 - Transfer Case problem of the 2004 Ford Explorer
The car involved is a 2004 Ford Explorer. The vehicle identification number (VIN) of this Ford Explorer is 1FMDU73E94_. The vehicle continued to go into 4- wheel drive on its own. The vehicle accelerated, then stalled. The mechanic was unable to duplicate the problem. There were several times when the vehicle was placed in reverse or forward the vehicle would buck. This issue happened on Saturday, October 2, 2004.
#11 - Transfer Case problem of the 2003 Ford Explorer
The vehicle involved is a 2003 Ford Explorer. The vehicle's vehicle identification number (VIN) was 1FMZU73K93_. Clutch in transfer case defective. Causes vehicle to shift into 4 wheel drive unexpectedly. It was 02/19/05 when this transfer case issue happened.
#12 - Transfer Case problem of the 2003 Ford Explorer
I have a 2003 Ford Explorer XLT 4x4, I have had nothing but problems with it, a few months ago I took it to the dealership because the abs light was on and the 4x4 was not working properly, they supposedly fixed it and told us they replaced a speed sensor, they also found 2 rear axle seal leaks and supposedly fixed those, then in October of '05 I took it in to the dealership because it was jerking between 30 and 40 mph and upon acceleration on hills not mention that I could hear something happening underneath my vehicle, they put it up on the rack and came back out and said the clutch in the rear end was scorched and needed to have the whole rear end replace, so I did but when I was driving it back home after the repair it started jerking again, and after several weeks of worry and wonder another dealership tells me that the transfer case is bad, my Explorer is trying to engage itself in 4x4, so now I am having the transfer case replaced! my Explorer has 41,000 on it right now and Ford has not been much of a help, I have to pay $1500 for the transfer case, I will never buy another Ford product, I will buy a foreign car. Ford really needs to look into all of the complaints and technical service bulletins on these vehicles and I will do anything I can to promote that. The failure date was Wednesday, Jun. 1, 2005.
#13 - Transfer Case problem of the 2003 Ford Explorer
The reporting person's vehicle is 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. This issue happened on Friday, May 11, 2007.
#14 - Transfer Case problem of the 2003 Ford Explorer
Vehicle identification number (VIN): 1FMZU74W93_. 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. The failure date was 01/30/2008.
#15 - Transfer Case problem of the 2002 Ford Explorer
The vehicle having this issue was a 2002 Ford Explorer. The VIN of this vehicle was 1FMZU73E32_. When coming to a stop on an incline transmission shifts to neutral, causing vehicle to roll backwards. Dealer stated there is a TSB on this issue, to refill transmission fluid. Ford has no remedy for it at this time. Transmission fluid leaks from converter housing into transfer case. It was Friday, July 12, 2002 when this transfer case issue happened.
#16 - Transfer Case problem of the 2002 Ford Explorer
The vehicle is a 2002 Ford Explorer. The VIN of this vehicle was 1FMZU73EX2_. When transmission shifting, jerky, vibrating feel. Vehicle is in for it's 8th visit. Total down time has been in excess of 6 weeks. Numerous attempt to repair as follows: download of program- 3 times, flush out transmission, replace filters, adjust tramsmission, replace spring in transmission, replace torch converter, tear down transfer case, replace gears. I am in process of negotiating with Ford to have them buy back vehicle.
#17 - Transfer Case problem of the 2002 Ford Explorer
The car is a 2002 Ford Explorer. While driving approx. 40 mph, vehicle suddenly went into 4 wheel drive low range. Occupant was wearing seat belt and car came to an abrupt stop. Accident was avoided due to light traffic this day. Car is @dealer 4 repair. Dealer claims computer that sends signal to 4 wheel drive transfer case failed due to cold weather and sent faulty signal to engage 4 wheel drive into low range. Temp was 40 deg. That day. I am concerned about the stress put on all of the internal drive components due to this sudden engagement. Dealer says they checked for outside damage, but damage will most likely be internal I. E. Transmission, transfer case, shafts, engine, drive assemblys. The day b4 we traveled on the interstate at speeds between 60-70 mph. If this had occured at this speed it would have been much worse. Wife went forward during engagement and strained her shoulder. She was wearing her seat belt though. Dt. This problem occurred on Mon., Nov. 25, 2002.
#18 - Transfer Case problem of the 2002 Ford Explorer
The vehicle is a 2002 Ford Explorer. The vehicle had a crash. It was during the fast freeze when this incident took place. We went from 45 degrees to 20 degrees with in 2-3 hours. It was raining at first then switched to ice & snow. We put the 2002 Ford Explorer in 4x4 drive due to the weather conditions. As we were entering the express way we loss control of the truck only going 28 miles per hour. We spun out of control and hit the guard rail. It was as though we had no 4x4 drive. We called the police to get a accident report for our insurance. We then took the truck a week later to martin Buick to fix the body damage to the left side of the truck. They took the truck to lasko Ford across the street to work on the 4x4 system. They took the clutches out and drained the transmission fluid. They found damage to the clutches. These parts were blackened and glazed over. They said that this looks like wear and tear for this truck and that the truck was not maintained. We regularly changed fluids and the manual states that the truck does not need maintenance until 150,000 miles. I asked how could a new truck have so much damage to the 4x4 and they said that it must have been in 4x4 wheel drive for a long time. I know and so do my passengers that this is not true. The dash board always indicated 2 wheel drive not 4x4 unless I put it in 4x4. The automatic 4x4 never turned on the 4x4 drive I have always had to put it in 4x4 if I needed to use it, which has only been one other time. So for a truck that is one year old and only been driven in 4x4 wheel drive twice there seems to be an awful lot of damage to my clutches and my fluid so burnt. The four wheel drive on this truck. I will have the module that controls the "control trac" 4x4 wheel drive system tested to see if it fails to activate or DE-activate the 4x4. Then I would like Ford to fix the problem out of their own expense and stop giving their clients the run-a-round and to reimburse me for my time and expenses. This problem occurred on Sat., Mar. 8, 2003.
#19 - Transfer Case problem of the 2002 Ford Explorer
The vehicle having this issue was a 2002 Ford Explorer. The Explorer has done about 21,000 miles in 2 and 1/2 years. About 2 months ago, it started having big clunks in the transmission when cold and even a grinding sound. Seemed to be when vehicle was being turned in either direction at low speed. The dealer replicated the problem and ordered and installed a "new clutch" in the transfer case -there was some kind of "fluid leakage. " problem is now worse, was replicated with the mechanic in the car and the dealer has it back in for another attempt at fixing it. My wife won't drive it anymore. A few months ago it used to have a loud squeak when the vehicle went over speed bumps slowly and this was eventually found and "fixed. " I wonder if the clunk in the transfer case is not that at all, but a loose/worn front suspension part giving way or losing tension when the vehicle is turned in either direction. Perhaps associated with the strut on the right side but not sure. Dealer has tried to be responsive and is not the problem. Any one else have a similar problem?. This transfer case issue occurred 11/19/03.
#20 - Transfer Case problem of the 2002 Ford Explorer
VIN of the vehicle was 1FMDU73W62_. 2002 Ford Explorer 4x4 straining and banging sounds in drive train when in 4x4 mode and when cornering in this mode causes vehicle to become hard to steer and can feel vehicle shudder as banging occurs. Was taken to greiner Ford on 12/04/03 the day problem started and was told by service advisor jim feiler that Ford technical support has been advised of the problem and that they do notice all symptoms I brought vehicle in for but they do not know what the problem is and thus are not authorized by Ford to repair even though vehicle is still under full warranty. I was then told they feel vehicle is safe to drive which I feel is interesting since they acknowledge they unit has a drive train problem but do not know exactly what the problem is, so how can they be sure it is a safe vehicle. This problem occurred on Dec. 4, 2003.
#21 - Transfer Case problem of the 2002 Ford Explorer
The vehicle was a 2002 Ford Explorer. Power train. . . Transmission needs to be replaced. . . . Transfer case was replaced before warranty ran out. . . Have 40,000 miles on truck. Was told it would cost $3350 to fix, I asked for help from my salesman and Ford knocked off $1700. 00 leaving me to pay $1650. 00. I had no warning signs until the speedometer stated 30 miles per hour while the I was going 5 miles per hour. Then the high pitched whining noise started. The transmission should not give out at 40,000 miles. This transfer case issue occurred Saturday, January 10, 2004.
#22 - Transfer Case problem of the 2002 Ford Explorer
The vehicle is a 2002 Ford Explorer. Vehicle identification number (VIN): 1FMZU74W22_. 4x4 light on dash would sporadically flash on and then go off. During a snow storm, four-wheel drive failed to work, causing the car to slide on roads. Had to buy snow chains to get the car to a dealer. It took two visits before dealer could diagnose problem and replace a 4x4 electronic shift module part # 2c5z*7e453. This transfer case problem happened on Friday, October 31, 2003.
#23 - Transfer Case problem of the 2002 Ford Explorer
The vehicle involved is a 2002 Ford Explorer. The vehicle identification number (VIN) of the car was 1FMZU74EX2_. The vehicle went into four wheel drive on its own. The manufacturer informed the consumer it was not covered under warranty. It was Mon., Nov. 10, 2003 when this transfer case issue occurred.
#24 - Transfer Case problem of the 2002 Ford Explorer
The vehicle involved was a 2002 Ford Explorer. The vehicle identification number (VIN) of the car was 1FMZU72E12_. My transmission shifter hard a few times ( loud "clunk") for some time now. I then lost 4 wheel drive. I am unable to select high four or even low. The low button no longer eluminates and shifts to low. I discovered I lost 4x4 mode while accelerating from a stop in the rain and my rear wheels spun wildly. I am out of warranty. . What do I do. Ford definately has a problem with this the automatic transmissions. I have about 48. 000 miles on vehicle. It was purchased used 3 months ago. This transfer case issue occurred 11/25/04.
#25 - Transfer Case problem of the 2002 Ford Explorer
Bought Ford Explorer (2002) used from Toyota dealer. Drove fine for over 6 months. Beginning in March (2005), upon acceleration (esp. On hills), vehicle lurches/shudders as it gains speed. Have taken it to 3 different Ford dealers, with no resolution (initially said that my new tires were 1/4-inch different in size. . . Tires were replaced and problem continued). Continuous lurching finally fried the gem module (and front/rear speed sensors). Ford still did not have an answer. Took it to reputable local mechanic who determined that it was not the tires, nor sensors, but a problem with "slop" in the transfer case. This slop made the 4x4 auto sense slippage and compensate, but more slop meant more slippage and more compensation, hence the repeated lurching feeling. Graphical electrical chart indicated that 4x4 was engaging and disengaging approximately 40x a second. After-market warranty wouldn't cover repair at local mechanic, so brought car to Ford dealer (6th time), who "think" problem is in the transfer case. This issue happened on 03/01/2005.
#26 - Transfer Case problem of the 2002 Ford Explorer
My complaint is in regards to the transfer case selection module on my 2002 Ford Explorer. Dealership indicated that the selection module is a common problem, but still want to charge full price for a new selection module when it's just a small plastic piece inside the module that fails. It was Jan. 5, 2005 when this transfer case issue occurred.
#27 - Transfer Case problem of the 2002 Ford Explorer
The car was a 2002 Ford Explorer. : the contact stated while driving 15mph in snow the vehicles four-wheel drive would not engage. Several attempts were made to activate the four-wheel drive with no success. Therefore, no repairs have been made. This transfer case issue occurred Thursday, Feb. 2, 2006.
#28 - Transfer Case problem of the 2002 Ford Explorer
The car involved was a 2002 Ford Explorer. The vehicle's vehicle identification number (VIN) was 1FMZU73E92_. : the contact stated while backing out of the driveway the vehicle automatically engaged into 4 wheel drive low. The vehicle would not disengage, it was pulled forward and parked. The contact was instructed by the dealership to slowly drive one and a half miles to the service department. The dealer was able to disengage the 4 wheel drive low however; was unable to duplicate the problem of the 4 wheel drive automatic engagement. The manufacturer was alerted. It was 04/25/06 when this transfer case issue happened.
#29 - Transfer Case problem of the 2002 Ford Explorer
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. This transfer case issue occurred Jun. 1, 2006.
#30 - Transfer Case problem of the 2002 Ford Explorer
The vehicle involved was a 2002 Ford Explorer. Transfer case failure. Dealer-ted britt, fairfax, va refuses to cover under power train warranty. This transfer case issue occurred Sat., Jul. 8, 2006.
#31 - Transfer Case problem of the 2002 Ford Explorer
Vehicle identification number (VIN) of the vehicle is 1FMZU72E22_. 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. The failure date was Jul. 12, 2006.
#32 - Transfer Case problem of the 2002 Ford Explorer
The vehicle involved is a 2002 Ford Explorer. Vehicle identification number (VIN) of the vehicle is 1FMZU74K42_. : 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. It was Aug. 16, 2006 when this transfer case issue happened.
#33 - Transfer Case problem of the 2002 Ford Explorer
The car was a 2002 Ford Explorer. : 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. This problem occurred on Thursday, August 31, 2006.
Other Power Train related problems of Ford Explorer:
|Problem Category||Number of Problems|
|Automatic Transmission problems||732|
|Overdrive Light On problems||320|
|Power Train problems||237|
|Differential Unit problems||225|
|Transmission Failure problems||160|
|Transmission Solenoid problems||120|
|Transmission Gear Slipping problems||119|
|Automatic Transmission Column Shift problems||83|
|Axle Assembly problems||76|
|Transfer Case problems||70|
|Automatic Transmission Torque Converter problems||65|
|Power Train Driveline problems||52|
|Transmission Not Go Into Gear problems||51|
|Transmission Noise problems||46|
|Transmission Slip Out Of Gear problems||42|
|Noises During Shifting problems||37|