Transfer Case problems of the 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.

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.

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.

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...

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.

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.

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???.

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.

: 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.

: 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.

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.

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

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.

: 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.

: 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.

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.

My four wheel drive failed, while electronic light showed car in 4 wheel drive. Car slid backwards into a ravine. On snowy road. Local Ford dealer did not know how to fix it, but problem was eventually tracked to a faulty electronic module that Ford knew about. This caused the solenoid that engages 4 wheel drive to fail/ this was an extremely dangerous situation. I was driving over a snowy mountain road previous day and could have slipped off road if it failed one day earlier. I see numerous examples of the same problem. Why doesn't Ford respond?.

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.

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.

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.

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.

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?.

The vehicle went into four wheel drive on its own. The manufacturer informed the consumer it was not covered under warranty.

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.

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.

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.

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.

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.