Five problems related to axle shaft seal have been reported for the 2003 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Ford Explorer based on all problems reported for the 2003 Explorer.
Purchased a 2003 Explorer XLT in November 2003. Within a few months noticed a leak that originated from differential area. Took to dealer was told a seal had to be replaced and everything should be ok. Took a family trip recently, the first one in the Explorer on March 17, 2007 and rear axle seal failed on a 1,200 mile round trip. Called Ford customer service and explained what happened, I even explained there were several TSB concerning my issue, I was informed that it was not a recall therefore it wasn't covered. I was told by Ford to go and have it diagnosed by local dealer, same one that fixed the problem originally. I had problem's diagnosed, called Ford and was told that dealer would provide "customer care after warranty". Called dealer waiting for reply for next step. My Explorer only has 33,600 miles while 1,200 miles were placed in the last few days, and warranty expired 4 months back.
- the contact owns a 2003 Ford Explorer XLT. The contact stated that the vehicle was making noises, wining, and grinding. The contact stated that the differential system failed and needed to be replaced. Also, the following components needed to be replaced: clutches, ring, pinion, carrier bearing, pinion bearing, and pinion seal. The contact had to update the axle seals. At the time of the original failure the vehicle had an odometer reading of 37,000 miles and the warranty had just lapsed. The contact did not believe that the weather was a factor, and the sounds were always when she was in the process of accelerating. The contact stated that it started very slowly and became an every day occurrence.
At 58,000 miles, both left and right rear axle seals developed substantial leakage necessitating immediate repair. Ford dealership service department made no mention that this was a known problem and required full payment by me for cost of replacement.
Rear axle noise. Started at about 34,000 miles but I did not bring to Ford until just after the 3 year warranty. Ford would do nothing and said repair was about $2,000. At 42,000 now and noise is getting worse.
Had to replace rear axle seals on 2003 Explorer with 500 on new vehicle.