Axle Assembly Problems of Ford Explorer - part 2

Roar/whine from rear end @ 40-65 mph. Stops when foot removed from accelerator.

See all problems of the 2002 Ford Explorer 🔎.

The contact has a 2005 chalet, when going on vacation yes the axle broke. The trailer was being towed at 55-60 mph. When the axle broke it caused damage to several parts of the travel trailer and tire. There was smoke damage from the tire and structural damage to the cabinets and under carriage. The rear axle that broke was the only axle on the trailer. There was no damage to the vehicle that was towing the trailer. The trailer was towed to the dealer, and there has not yet been a determination about the repairs. Upon the vehicle owners inspection, they discovered that the axle was covered with rust and had many cracks. The police were called, but no police report was filed since there was no accident.

See all problems of the 1999 Ford Explorer 🔎.

Two instances of whining noise at 50+ mph and fluid leakage from rear axle seal 2002 Ford Explorer limited. The first one caused loss of control when accelerating on highway; resulting in coming to rest within inches of concrete barrier after jerking across several lanes. Difficult to determine since rear transaxle fluid leaks down drive shaft to brake assembly. I only notice because I perform a monthly inspection of the undercarriage. Noticed significant corrosion of brake assembly where fluid is running into the wheel assembly. Only when leak is significant will fluid drip onto surface below rear axle. Dealer noted Ford engineers are aware of problem but expect the consumer to pay for repairs. First replacement of rear axle seals at 39000 miles; second at 50000 miles. These seals should last longer. Second instance had vibration when engaging the vehicle in reverse and oud whining noise/ vibration from rear; then fluid leakage. This is a major safety issue for the Ford Explorer. Several work colleagues had the rear axle sieze due to lubricant loss with similiar symptoms, almost causing serious accident. My dealer acknowledges (bill estes, brownsburg, in) that many Explorers (2002-2005) have this problem and Ford motor company engineers are evaluating; as a dealer there is nothing they can do. Ford has not indicated a fix other than to check fluid level, replace rear axle seals, and/or the rear unit. This is a significant hazard since in most cases the vehicle owner will not know there is a pending failure due to the fluid leaking down the rear axle drive shaft toward the brake/wheel assembly. The whining noise will increase as fluid level decreases with risk failure and loss of control. This problem is far more common than reported due to the difficult nature of observation of leakage. One has to crawl under the rear transaxle and carefully inspect the two axle seals to look for signs of corrosion and fluid leakage.

Loud thumping noises coming from front end of 2002 Ford Explorer. Ford says they are normal. It didn't do this when we bought it. Also there is a loud whining noise coming from the rear end. Rear end has been replaced onced. Problem disappeared for about 10k miles after it was replaced. Wife is afraid to drive the car as we have three newborn babies.

I have had numerous mechanical failures with my 2003 Ford Explorere. The front wheel brearings and front axle bearing have failed. The rear axle has been rebuild twice and replaced once. Another rebuild is needed. Total mileage is 49,000 miles.

See all problems of the 2003 Ford Explorer 🔎.

Hello, I own a 2002 Ford explore XLT with 50,000 miles v-6. In the rear end of the vehicle there is a grinding noise that is in a rythmic patteren. I have scheduled an appointment next Tuesday but was wondering if there is any recalls that I should know about. After reading several forms from other Ford Explorer owners it sounds as if there is a reoccouring problem.

Loud whining noise in the rear differential . . The bearings are bad and the seals are leaking.

Multiple wheel bearing failure on 2002 Ford Explorer 4x4, 42,000 miles. Loud noise prompted action before complete failure. Complete failure may have resulted in wheel lock-up and possible crash. Despite complaint and resquest for the repair to be covered given limited mileage, no assistance from Ford motor company. Dealer did replace one unit at no charge. Ford provided no assistance. Personal knowledge of another owner with similar problem, had to replace all four wheel bearings. This is certain to become a major safety problem as these cars age if Ford is not held responsible for the defect and forced to take preimptive action to save lives.

Vehicle purchased in 2003 after 1 year roaring noise began in rear axle. Vehicle taken to dealer and differential carrier assembly replaced. Vehicle now having the same problem with differential assembly. (roaring noise).

I have a 2002 Ford Explorer that has had many problems with the rear end. There is a constant leak, on the right side, that can't ever seem to be fixed. The first time I took it in to the dealership they said it was the axle seals and they replaced them. Then it happened again and they said it was my hub which they replaced. It happened again and they said that a groove had been worn in the axle and that was causing the leak. Less then a year later the other side of the rear end is leaking.

While turning the vehicle in either direction the front axle locks. Owner contacted the manufacturer, who sent an engineer to evaluate this problem. Currently, manufacturer does not have a solution for this problem.

See all problems of the 2004 Ford Explorer 🔎.

Abs light was on. Also, back axle was replaced. Currently, the abs light was on again. The abs light was on a total of 3 times.

Drive train and rear axle have persistent shudder and binding when shifting gears 2-3 and upon acceleration dealership has been notified and will not resolve problems that have been id'd w/ service bulletins for the 5355-rw assembly and the rear-gear lubricant ratio mix-up inthe sealed rear housing even though they have rec'd protocal from mfg. On the procedure and/or replacement partsas being available since Mar 2001 this has been noted in other complaints that have resulted in severe damage done to the rear axle and wheel components but they do not see this as a problem when in fact it can result in vehicle failurethat may result in injury or evem death. I personally see this as blatant negligence on the dealerand mfg. Part of resolving this issue. My Explorer exhibited trouble since July'04 and was mfgd. In the time frame that a defect was brought to Ford's attention in this matter. What do they want a certain number of deaths or injuries?.

While driving consumer heard a loud noise coming from the rear axle/driveshaft. Dealership was notified, but did not resolve the problem.

I purchased a new 2003 Ford Explorer XLT 2wd in September 1, 2003. With 20,000 miles on the vehicle I noticed a whine from the rear end that was audible from 45 mph to 65 mph. The noise would stop when I let off on the gas and would resume when the gas was reapplied indicating a bearing failure. I took the vehicle to leith Ford of wendell, nc, where I purchased the vehicle. They replaced the rear axle assembly under warranty on July 9, 2004 with 21,899 miles on the vehicle. The replacement rear axle made the same whine from 45 mph to 65 mph indicating rear bearing failure. The complete rear axle assembly was replaced by leith Ford under warranty. The rear axle assembly was ordered from Ford on October 20, 2004 with 32980 miles on the vehicle. The assembly was received and installed with 36,000 miles on the vehicle. With 63,280 miles on the vehicle I returned the vehicle on October 17, 2005 to leith Ford to check out the same whine in the rear end from 45 mph to 65 mph. They confirmed that the rear bearings were failing and ordered a rear differential kit to rebuild the rear axle assembly.

1st time was the rear howling noise at highway speeds, primarily during acceleration. It was remedied once foot was off the gas pedal. Inner/outer axle bearings, racers, pinion seal were replaced. 2nd incident occured less than 30 days, and 3000 miles later, when the truck decided to pull me from 75 mph to 25 mph in seconds. There was a major leak under the rear axle, and the truck required towing. There was a major replacement to the rear end, do not have the documentation at hand, but it was expensive. Now, 2 years later, 30000 miles later, the rear end needs an expensive part for replacement. When I made sharp right/left handed turns, there was a shudder, a grind, that was coming from the rear. Ford service notified me same day that a pack needs to be replaced for $725, about the same region where original problems have occurred. Should I expect to see similar problems continuing during the next 30k miles? I feel that I have been pretty caring to the vehicle by having it serviced every 3k miles. Didn't see this coming. How many more complaints until recall?.

My wife and I bought a new 2003 eddie bauer Explorer VIN 1fmdu74k23zb45658 with 1 mile registered on it. We purchased it 9/15/03, since day one the vehicle has had a whine in the rear, a vibration at 55 mph. Complaints to Ford as well as to the len stoler dealership,11275 reisterstown road, owings mills, MD 21117 phone 410-356-2635 has brought nothing but frustration. The vehicle can't be fixed is what we are told! but after 5 visits, it is being worked on now for the vibration 12/04/03, the whine in the rear still cannot be fixed. Notifications from Ford to its service centers: driveline axle concerns from Ford motor company 509000 dealing with problem 17054 quote: 2002- 2004 Explorer 4 dr-rear axle whine, some 2002-2004- Explorer 4dr vehicles may exhibit axle whine at normal or during acceleration. To service, perform normal diagnostics. If specific root cause is not identified, be aware that engineering is currently investigating via the quicker service fix process. A service procedure will be published as soon as it becomes available, please continue to submit concern reports for any vehicle which exhibits this condition. Monitor oasis for updates. -this is one of our problems, dealership cannot fix it at this point, so we are stuck with a whining rear in new vehicle. The second problem with our vehicle is trying to be fixed, quote: 17107 2002-2004 Explorer 4x4 driveline vibration or drone/boom at highway speeds. Some 2002 -2004 Explorer 4x4 vehicles may exhibit a vibration or drone/boom at 55 - 75 mph. Electronic vibration analyzer (eva) reading will fall under 1st order rear driveshaft at 2700 rmp . If concern is till present in 3rd gear and isolated to the driveline, a premium balanced driveshaft is available. Install 3c5z-4602-aa driveshaft assembly, referring to workshop manual section 205-00 for procedure. If vibration persists after replacing driveshaft, reindex at pinion flange 90 degrees at a time, for 360 degrees, until vibration is minimized.

Soon after purchase the Explorer (2wd) developed an axle whine from 55-70 mph on acceleration. It's quiet on coast. The local dealer found a TSB (#16898). They replaced the driveshaft as specified. The only change was the range of the whine, now 58-63mph. Back to dealer on 1/8/04. They said a fix was in the works, call back in 3 months. Called today (4. 21), no fix and no date. Sure sounds like a bad ring/pinion to me. . .

About a month after we purchased our 2003 Ford Explorer XLT, we noticed a whining noise from the rear of the vehicle. We notified the dealership and they refused to work on it. They said Ford is investigating the noise and could give no time frame on when if would be fixed. Asked us to just be patient. . This is totally unacceptable, and the way customer relations has been dealing with us, Ford should be embarrassed. We are currently research the lemon laws. We do not want a brand new vehicle that makes this awful whine (which is getting worse day by day). Who knows if it is safe, given Ford's trac record!.

My 2002 Ford Explorer XLT has expierenced all the power train problems that I ahve found on this site. My dealer ahs been admirable in trying to resolve these problems but it seems we get one fixed and another starts. The firs was the transfer casr had a shutter in it between first and second gear , then the rear end had a bad bearing, then the left rear axle had a bad wheel bearing, then the vehilce was staying in four wheel drive all the time, this happened on a trip this fall bare ground. Then the latest is the transmision is going to neutral at stop signs and red lights by itself. The vehile then sits and revs until with a bang the transmisson engages again.

Excessive whining noise coming from the rear differential/drive axles/driveshaft area of the vehicle at speeds between 50 and 60 m. P. H.

Purchase vehicle on July 30, 2003. Rear axle whine during speeds between 45 - 60 during acceleration/ decelleration diagnosed on 13 October 2003. Advised that engineers were working on a fix and no service was to be performed. Very displeased at the attitude of Ford customer service representatives and the lack of service received with Ford vehicle. Filed complaint with settlement dispute board and with better business bureau. Next step is to contact attorney to file lemon law. Also, consumers need to get out information to the public that Ford is selling these vehicles knowing there is a problem and is not willing to fix them.

I bought a 2003 Ford Explorer 4wd, v8 - sept. 22, 2003. About 3. 5 weeks later it began to shake and made a loud noise. I haven't gotten 1100 mile on it before it began its downward spiral. I took it into be repaired on 10/13/03 regarding the whining but I forgot to mention the vibration-- it only happen on 2 occasion thus far. But the whining is constant - around 50 mile and above. I was by the service person the engineers are working on it and I am to wait until they find a cure for it. I am not trusting them with my safety, I was told it was in the driveline/axle /driveshaft- the name changes but still the same explanation - no fix as of yet. Could be long-term or not at all. I want this vehicle replace - ASAP.

Rear end noise (grinding) in our 2002 Ford Explorer during DE-acceleration. First time to dealer 8/25/03 mileage 30,901, nothing done, 2nd time to dealer for the same problem 11/03/03, mileage 36,930 could not find problem. Problem seems to go away, came back around 75,000 miles. Took vehicle to another dealer and complete rear end was replaced at a cost of $2600. 00. Not sure why it was not detected with the first time to the dealer?.

Ford Explorer rear end had high pitch noise: mechanic had to place a new rear end in the vehicle: four wheel drive locked into low gear and would not release: replaced control switch but 4x4 high light blinks.

While traveling 55 - 65 mph a high pitched whinning noise would develop in the rear portion of the vehicle. The noise would subside as the pedal was released. However the noise would increase as the gas pedal was slightly pressed to advance speed. Took to dealer on 6/11/02. Mechanic claims to know what is causing noise. Truck is sitting up on rack apart and the tool to remove axles is on national backorder. Needless to say the loaner vehicle I am currently using has the same sound, but is not as severe at the moment. I feel this may be a design problem that may not be fixed as easilly as hoped.

While driving, rear axle broke on driver's side. Consumer lost control, causing a vehicle roll over. Driver injured.

See all problems of the 1998 Ford Explorer 🔎.

April 2, 2002, while driving on a flat, straight freeway, the rear driver's side axle broke. The tire came off the car and sailed through the air. I lost control of vehicle immediately, resulting in a severe skid and vehicle roll-over. Crash resulted in driver sustaining large bump on head from roof collapse and a concussion. Numerous cuts, bruises, and severe muscle stress/strain of neck, shoulders and back. Also received deep contusion on chest due to seat belt retraction. I feel blessed to be alive to make this report. 2 weeks after accident still experiencing body pain. I can just now talk about the roll-over without crying. My family and myself have been through hell. Vehicle is a total loss.

I feel this SUV is very unsafe Ford and dealership state otherwise. No safety defect recorded.

While traveling at approximately 20 mph vehicle was making a rumbling noise, and vehicle was being pulled to right. Consumer suddenly lost control of steering and brakes. Consumer was able to bring vehicle to a stop. Dealership examined vehicle, and determined that front wheel bearings have blown apart, and axle popped which resulted in loss of steering and brakes. Please provide any additional information/attachments.

Front left steering knuckle broke, axle separated from vehicle, vehicle went left and crashed. Filed by richard rumplik.

See all problems of the 2001 Ford Explorer 🔎.

Consumer states a strange noise is made when pressing on the accelerator, dealer stated the problem was the front axle and that there were scraps of metal breaking off the axle, consumer is requesting a new vehicle and states that the scraps of metal could be damaging other parts of the vehicle.

After noticing fluid all over the driveway truck was taken to the dealership. Dealership stated that fluid was leaking from front axle. Repairs were made at owner's expense. A service bulletin was issued about this problem. Please provide any further information.

See all problems of the 1996 Ford Explorer 🔎.

The consumer states that both front axles failed in the same way: the rubber sleeve split allowing grease to come out causing the moving metal parts to disintegrate. The consumer doesn't drive over rough terrain, although I would expect an all wheel drove to be able to do so w/out damage to the axles. The consumer's mechanic has replaced the axles on three Explorers in two months in an area with a small population seems more than coincidence.

See all problems of the 1997 Ford Explorer 🔎.

Consumer had seen left front tire show initial separation. Consumer believed it was the axle.