Five problems related to axle shaft have been reported for the 2002 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford Explorer based on all problems reported for the 2002 Explorer.
Wheel bearing failures-4 in a 6 month period of time-cost over 1700. 00 too have these repairs-Ford will not help out and there customer service is a joke. I have a child that is always with me and 2 times it could have been bad.
Front end of my 2002 Explorer made a "clicking" sound when driving and turning. On June 16 2003, Ford inspected and found both the right and left front axles were defective. They replaced them. On September 4, 2003 the same problem was occurring, Ford again inspected and found the axles put on the vehicle in June were also defective. One year later I am now having the same problem. I took my vehicle in for an oil change and the mechanic said there is a problem with the front axles. There has to be some sort of issue with this part. The potential failure of this part will lead to an accident. My family rides in this vehicle every day, someone is going to get killed.
The initial problem with the rear-end differential unit was a whining noise which the Ford dealer's service rep. Identified and immediately said it should be replaced. The new rear-end unit did not whine but within 3 1/2 months a vibration started and was returned to the dealer for a total of 6 different occasions to repair or fix this problem. Both the left and right rear axles were also replaced and another rear end differential unit was installed. At each service visit, the dealer's service manager and mechanic were completely involved and were very perplexed at the problem. My Explorer was at the dealer for about 30 days on one service visit and a total of 42 days over the 6 total service visits for this problem. Persistent fluid leaks and a recurring vibration has prompted me to submit a "lemon" letter to Ford.
Vehicle purchased new, had a pinion noice in rear differential since purchased. Dealer changed rear differential and a week later it developed a leak due to blown axle seal. Rear differential then developed a noise when accelerating into a turn from a stoped position. Dealer added an additive to rear for limited slip unit. Noise is still there on turns but is very light. All this has occured since purchased new and 14,000 miles.
Vibration and drone/roar sound at speeds of 64mph and greater. 4 attempts made to repair, problem still exists. Rear end assembly replaced as well as two axle shafts and drive shaft reindexed.