Transfer Case Problems of Ford Explorer - part 1

The contact owns a 2016 Ford Explorer. The contact stated while driving 35 mph, the vehicle shuddered abnormally with the check engine warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the transfer case had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 135,401.

See all problems of the 2016 Ford Explorer 🔎.

Our Explorer has had cascading warnings each time we drive the car for the past 7 days. Sometimes it takes a mile, sometimes it is immediate. The safety warnings include: 4-wheel drive fault, passenger air bag fault, forward collision avoidance not working, powertrain malfunction, restraint indicator light warning, pre collision assist- . Not all appear each time, and some change ( 4wheel drive fault/ power train malfuntion- restraint warning/ airbag seem to alternate. Power train shows with restraint. 4 wd malfunction shows with airbag). Each time it occurs the airbag warning illuminates. Dealer cannot work on it until July 16th. Sounds like TSB 23-2174, but have been unable to codes when I stopped by a dealer before July 1 we had no warnings. 48,582 miles. When faults appear- most systems appear to work, have tried 4wd and other modes and they appear to work. But cruise control, seatbelt chimes and others do not work.

See all problems of the 2020 Ford Explorer 🔎.

The contact owns a 2014 Ford Explorer. The contact stated while accelerating at slower speeds, the vehicle hesitated while shifting gear. No warning lights were illuminated. The vehicle was taken to the dealer where it was diagnosed that the power transfer unit (ptu) needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was informed that the VIN was not included in a recall related to the failure. The contact was referred to the NHTSA hotline. The failure mileage was approximately 93,000.

See all problems of the 2014 Ford Explorer 🔎.

I noticed transmission fluid on the garage floor. March 27,2021. Dropped the car of at the dealership where I bought the car. 2021 Ford Explorer st with 2120 miles I purchased on January 30, 2021. Problem was diagnosed as leaks at the transfer case seals on the transmission output drive train. The boots were leaking transmission fluid. The transfer case needed to be removed and the seals replaced. This resulted in waiting 6 weeks for the parts to be delivered and 1 week more to repair and install. Today I still do not have my car back. Week 7 will be next week when completion is estimated to be .

See all problems of the 2021 Ford Explorer 🔎.

My 2014 Ford Explorer XLT awd at 82,000 miles starting leaking oil from the transfer case. I was told by my mechanic that Ford is aware of this issue and has failed to do something about it thus far.

Transfer case makes a lot of noise I have to replace it. I am electric wreck steering makes a lot of winding noise.

See all problems of the 2013 Ford Explorer 🔎.

2013 Ford Explorer limited 4wd 3. 5l became undriveable in a matter of 4 days. It started as a squeal as I accelerated from a stop and quickly escalated to lurching, pulsating and bumping at all speeds. Mechanic initially thought it was a caliper that was locked up but when I brought it back 2 days later after the problem persisted and worsened he realized that the transfer case was faulty. He noted that Ford is notorious for faulty transfer cases and horrible warranties that end before the parts go. I'm told that my vehicle could lock up at any moment and cause me to not be able to react putting my families safety and those around me in danger. Help please! I'm told this is a common issue and not isolated to my vehicle. Multiple phone calls to Ford have me on hold for 15+ minutes with no sound and then phone call ends without the chance to talk to a representative. My vehicle had roughly 94,000 miles at the time. Repair cost was estimated between $3,000 - $5,000.

My car began lurching when I was driving and began leaking oil. When I took it in, I found out the pto needed repaired. The transfer case was filled with metal and covered in metal shards. Mechanic said the car wasn't driveable and would be dangerous to have on the road.

Transfer case leak and failure at 82755 miles. No apparent cause. Car lurched forward twice and almost hit vehicles in front of car.

Transfer case leak and failure at ~76000 miles. No apparent cause. Leak creates burning smell in cabin of vehicle.

2013 Ford Explorer transfer case.

94000 miles the transfer case burst and when 70000 miles charging cycle does not work , the vehicle suddenly stops.

Upon driving the car, the transmission was not fully engaged. In first gear, a loud rattling sound was heard. Car would not proceed forward. Brought to local mechanic who diagnosed the problem as a faulty transfer case. Said this is a common problem with Ford as per numerous complaints online with no recall issued by Ford.

I am just over the power train warranty on my Ford Explorer and $2000 transfer case ptu or pto repair. Crazy. I am reading up on it and found many complaints online. . Read more...

See all problems of the 2015 Ford Explorer 🔎.

Over the summer, I began smelling fumes in my vehicle cabin. The local dealer told me it was due to the recall, and I had no reason to be worried. Unfortunately, due to housing issues, the recall got pushed to the back burner. So, I had an appointment scheduled for yesterday, 12/11 to have the recall on my vehicle fixed. Then last Wednesday, 12/5 my car kept seizing when I was braking or accelerating, and I almost wrecked my vehicle multiple times. After ruling out the u joint or drive shaft, we then found the glistening leak on the ptu, and were able to deduce the smell as being diff fluid dripping down onto the exhaust and coming through the cabin. Since the vehicle was not driveable, the next morning, I contacted the Ford dealer, who put me into a rental, and we gingerly drove the vehicle to the dealer that afternoon. Yesterday, I get a phone call confirming what we suspected the problem to be. While on the phone with the service manager, he confirmed that this is definitely a known issue with multiple Ford models, and he is completely familiar with this problem. 24 hours into this, Ford is saying it's not their problem, and that there's no "promotions" that I'm eligible for. I'm about at my wits end. I have one child with special needs, and I'm a single mom. I don't know what to do to get this resolved and get Ford to fix their problem that is now costing me close to $2,000. To further describe the issue, when it finally got to its worst, when compressing the brake, you would hear a grinding noise and the car would jump as though it was going to stall. The same would occur as you were accelerating, and continue until you got to about 2000 rpm and steadily coasting. The dealer told me that the gears were so damaged they were unable to fix it. I will update this thread later with pictures of the transfer case that they took off my vehicle.

I was driving down the highway when the SUV shuddered and I heard something bouncing down the underside of the SUV, which isshudderong every badatthispoint so I stop seeif I could tell what the problem was. . . Indeed I did there was a large piece of my transfer case/ ptu missing I tried finding it with no luck . . I tried moving the SUV off the highway babying it jerked at 5 mph mind then awd light flashed and went right back off got out to look again yeah whole driveshaft hanging down. . . . Now outside my safety thank god this happened at low speed but think about the very large chunk of metal that shot out from under my SUV thank god no one was behind me this could have been very very bad please look into this if you would email me I will take pics next time I'm around the Explorer and email them back . . . Approximately 45mph when piece came off and 5mph when driveshaft fell down.

2nd time the transfer case has had to be replaced. 115k miles.

Total mileage 24326, brought to dealer for oil change and suspected exhaust smell in cabin. Mechanic's answer to smell "the smell is the ptu coming apart inside. The oil is black and there is metal filings on the plug. Transfer case needs replacement. " dealership service advisor says this is very common, ". . . Have done over a hundered. . . ". Was caught only because smell was mentioned. Scheduled inspection/oil change of transfer case not required for another 6000 miles. Vehicle has never towed anything and is not used off-road. Vehicle at dealer having transfer case replaced.

Transfer case has leak and needs to be replaced according to Ford. Vehicle has 62,000 miles and out of warranty. Leak was discovered at approx 57,000 miles but was assumed to be a leak from sloppy oil change. Reported to Ford customer assistance on 8-2-2018. They said no warranty coverage applies. Told to save receipts for repair work in case of a NHTSA recall.

Sudden onset of grinding noise. Upon examination and confirmation of engine oil, coolant and transmission fluid levels, determined that transfer case/ptu was failing. Caused loud clanking and grinding noises while in forward gears which was worsened when turning. Gearbox locked up while in turn and stopped vehicle in roadway while crossing opposite traffic lane. No signs of fluid leaks from transfer case or transmission.

Transfer case is gumming up and tearing up my pto and causing grinding while accelerating. Spoke to my mechanic and he said that Ford is aware of the problem but has yet to issue a recall or extended warranty on issue. Will cost $1600 to replace pto.

My car has 64000 miles on it and was purchased in January 2014. The transfer case has failed and caused massive amounts of fluid to leak from the vehicle. The fluid could be seen on my driveway and my carport floor, and it was an $1850 fix at the mechanic. There was, according to the dealer, a recall for a similar issue with certified pre-owned Ford Explorers, and they said the transfer case was cracked, along with the valve. Additionally, there is an odor of propane or similar coming from the exhaust vents inside the vehicle. It's worse when it's on air conditioning, to the point where I actually have to put the windows down.

My 2011 Ford Explorer had a faulty transfer case, which set me back $2000. 00. The issue I was experiencing was a grinding noise in my front end while driving. I would experience hesitation when increasing speeds, as if the transmission was slipping. While going in reverse, the car would stall and the gear would lock. I would have to put the car back in park and try to reverse again, in order to move. Mazda has the same issue with their transfer case, which is the same transfer case on the 2011 Ford Explorer!!!!!!! this car has major issue across the board. I just recently replaced the power steering rack, which was eventually recalled by Ford after numerous complaints. The 2011 Ford Explorer transfer case should be recalled by Ford. The transfer case can dismantle and cause a major accident while your are driving!!.

See all problems of the 2011 Ford Explorer 🔎.

I have a 2011 Ford Explorer and I absolutely hate it !!! ever since I purchased the vehicle , I have had many problems. I just had my power steering rack replaced , out of pocket, until Ford decided to recall it. Now, I had to replace the transfer case , which ironically went bad out of no where. The transfer case is a major issue with Ford vehicles and Ford refuses to recall it . I have had many many problems with.

Exiting from parking lot and speed of about 15 mph on a straight road, no pot holes, at about 100 ft from the parking exit, it hit an electric post. Left front suspension, fender, wheels,pillars, rocker & floor, radiator support, front lamps, hood,steering rock, cradle, transmission transfer case, front door and manny more damage. All are in left side. I checked the VIN but it is not on recall for power steering problem however I suspect power steering was the caused of accident. It is a major damaged and the insurance is not yet decided if repair or total wreck. I asked the Ford dealership to see on the diagnostic computer of the vehicle but up to now they have not yet check.

Transmission failure resulting from michelin incorrectly marking tire sizes: I had four michelin cross terrain p235/70r16 tires on my SUV. Two wore out and where replaced with michelin latitude p235/70r16 tires as the cross terrain model was discontinued. The SUV then started having transmission problems especially when accelerating and the transmission failed and had to be replaced. The new transmission immediately started having similar transmission problems also. After multiple specialists examined the SUV, the problem was isolated to the 4x4 module engaging the transfer case during acceleration. It was determined by measuring the tires that the vehicle in fact had sets of tires with different circumferences, even though the tires were marked as being the same size. When the circumferences of the tires are not the same it causes the 4x4 module to believe a slipping condition is present and engage the transfer case. The continual engagement of the transfer case results in damage to the transmissin. I contacted michelin consumer care four times over a two month period only to be totally ignored. Michelin has sold tires that are marked incorrectly as to size, which results in damage to your SUV, and they refuse to accept any liability.

See all problems of the 2006 Ford Explorer 🔎.

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 🔎.

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 🔎.

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 🔎.

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 🔎.

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 🔎.

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!.

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.

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.

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.