Axle Shaft Seal Problems of Ford Explorer

Leaking rear axle seal.

See all problems of the 2002 Ford Explorer 🔎.

Rear axle seals and wheel bearings. We have had to replace the rear axle seals on June 4, 2004 with 4, 000 miles, and on Jun 16, 2006 with 69. 600 miles. Also had to replace rear hub bearings and assembly on April 17, 2007 with 74,000 miles. This is obviously a recurring issue, and I have been told this is a common Explorer problem. All work on this vehicle has been performed by reputable Ford authorized dealers/service, and would expect work to last longer than 1-2 years.

I was told that the 2002 Ford Explorer has rear seals leaking. I need to get these replaced as soon as possible because I will have to replace the drive train if it fails. I have 119,000 miles on the vehicle, but I always had it serviced with Ford. I have done some research and apparently the seals have been failing at low miles. I felt the seals were defective because there were some with this problem with low miles. Apparently the dealers waited until the warranty expired. I felt if the vehicle failsed this would be a safety issue. Ford has produced more defective Explorers. I am now faced with a large repair bill.

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.

See all problems of the 2003 Ford Explorer 🔎.

- 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.

Thumping noise from drivers side front end in the wheel area. The noise is most noticeable at between 40 and 60 mph during acceleration. It also becomes a humming noise as the gas pedal is released and the car is coasting or decelerating. Had new tires put on then new brake pads and rotors. Nothing fixed the problem. Talked to my brother, another loyal Explorer owner, and he had same problem diagnosed as a bearing needing replacing. He also told me about a leak on his garage floor in the rear middle of the car where the rear axle is. I told him I have same exact spot of something leaking on my garage floor. We read about all the seal problems with the axle and needing to be replaced. He spent over $1000 on the front bearings and now in for another big bill for the seal problem. I see we are not alone in our Explorer disappointments. All with the same problem. Come on Ford, back up your vehicle and pay for these defects to your suvs.

I noticed a fluid leak from the rear axle of my 2002 Ford Explorer and took it to the dealer for diagnosis. It turned out that both the left and right rear axle seals had failed. The vehicle had only 75k miles on it when the leak began. I double checked the recommended service schedule to see if I had missed something but they do not recommend that the rear axle fluid be changed until 150k miles. So this is not a case of owner neglect. After some discussion at the dealer service center they informed me that this repair is fairly common on Explorers, mountaineers and aviators and that the repair kit has a newly designed seal. If there is a newly designed seal available, this strongly suggests that the original seals are insufficient. This is also proven by the fact that both seals failed, not just one. The cost of the repair was quoted at $490 ($380 of which was labor cost). This is too much to ask a consumer to pay for a part that was under designed and not properly tested prior to being put into production. Therefore, I believe these rear axle seal parts should be recalled and the oem should be forced to reimburse vehicle owners for repair costs. I also noticed that there are TSB's regarding Explorer, mountaineer, and aviator vehicles that may have been filled with the wrong rear axle fluid at time of production but have no way to get more information on this to see if my vehicle is affected. I would be interested in any information NHTSA may have.

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.

Brought my car in for a 60,000 mile checkup and was told that my axle seal was leaking and that the ring and pinion gear-rera kit/seals were needed to fix the problem at a cost of $1131. 83 plus tax. The advisor said that the seals rotted and then the leakage began and it went down hill from there. This same car had been in earlier this year with what we thought maybe a transmission problem. It was checked and we were told there was no problem but there wasn't any indication of axle leakage problem. I have researched other complaints here and there seems to be about 4-5 other people who have a similar problem and want to know why Ford motor company hasn't address this problem with a recall. Thee are a lot of other folks with the same problem expressing it out on Fordforum. Com. We have owned 4 Explorers and feel very disappointed that we need to spend this kind of money with a car that has only 60,000 miles on it.

There is a slight leek of differential fluid from the left axle seal. I now have noise at highway speed from rear end. Fluid level has remained good.

Yet more leaking read differential seals. Rear end howling also, has been for about 15,000 miles now. 79,000 miles currently. I will have to change the rear seals again, and will inspect for the howling noise again. May have to change pinion bearings!? as a mechanic, it is unbelievable to me that we would be having seal and bearing failures at such low mileages. Bad aluminum housing castings maybe? bad machining? too much slop at the rear half shaft, causing premature wear on the seal faces? what ever the reason, Ford is not making much effort to repair. And they seem surprised that folks are buying foreign trucks. (Toyota trucks).

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.

: the contact stated after having rear axle pinion seal repaired at a local independent repair shop the mechanic noticed the rear suspension coil springs were broken and needed to be replaced. The manufacturer was consulted.

2002 Ford Explorer, eddie bauer 4wd 4. 0l; 83k miles, for the second time on vehicle has rear axle seal leak. Rear axle seals and pinion seals replaced at 55k; humming noise/whine from vehicle at cruising speeds. Many similar problems reported online, and Ford TSB's issued, but no recalls. . Read more...

My Ford Explorer rear axke to diff. Seals are leaking oil, and the rear end is very noisy. Ford put new seals in at the cost of $340. 64 . The day I pickeded up the vehicle they were still leaking 30 miles later with the new designed seals in. I put the 2002 Explorer back in the garage to get the seals changed 6 days later. Sthe rear end is still very noisy, but the seals are not leaking for the time being. I called the Ford 800 number to complain and try to get my money back with no avail.

Rear axle has had recurrent leaks. These were repaired 3 times under warranty. On the fourth occassion the dealer replaced the axle. This was also done under warranty. Problem was firsted noted at just under 30,000 miles. Axle replacement was at 58,ooo miles.

The rear differential of my 2002 Ford Explorer xls is leaking at 41,000 miles. Noticed the liquid on the garage floor. After I brought it to a local dealer to look at it they tell me it is the axel seals and is 450. 00 to fix. Now I look at 2002 Explorer rear problems on the internet and they are epidemic in perportion.

See all problems of the 2005 Ford Explorer 🔎.

2002 Ford Explorer - rear differential axle seal began leaking at 23,000 miles and was replaced under warranty; started leaking again at 30,000 miles and the rear axle and seals were replaced under warranty; started leaking a third time approx. Eight months later and dealership replaced both axle seals; now 5000 miles later the seals are leaking again and the dealership is telling us they don't know why the seals continue to fail; in addition to the real seals leaking we have had to have the abs sensors replaced twice, the oxygen sensor once and a seat belt sensor once.

Consumer stated rear axle seals were leaking. Dealership was notified, but did not resolve the problem.

1999 Ford Explorer eddie bauer edition. . . We had gone out to dinner and when leaving the parking space it sounded as if we ran over a glass bottle. My husband looked around the vehicle and could not find anything. I got in the drivers seat and it felt as if the emergency brake was on (was not) and was very hard to move. We returned to the parking space, turned off the vehicle getting ready to call aaa for services. We both heard a "release" sound. He turned on the vehicle, backed up and we drove home very carefully. The next morning the vehicle was at the dealership to look into this mystery. The brakes were fine; however, they found the following to repair: *seals to brakes *rear axle pinion seal *both lower ball joints on the front end I was told the front right tire ball joints were completely worn down and the tire was just wobbly held on by the lug bolts. We recently purchased this vehicle and would appreciate your help in reviewing the past recalls on this type vehicle. This could and would have been an extreme hazard with probably extreme injury to the persons involved. Also, if you can please check the past history of the owners to make sure they have kept the vehicle maintained with any suggested recall items. Thank you, marlene morgan.

See all problems of the 1999 Ford Explorer 🔎.

The rear axle seals at the gear case have failed twice causing axle fluid to leak. The dealer has replaced each time saying that "Ford has an issue" with these seals but they do not have a lasting repair. Not all 2002 Ford Explorers have this problem.

The rear seal on the axle assembly had to be replaced 5 times on the consumers 2002 Ford Explorer. The consumer requested reimbursement.

Had to replace rear axle seals on 2003 Explorer with 500 on new vehicle.

The last repair was a third time the front end seal have failed. The service dealer customer service attendent state that he had six Explorers that morning for the same failure. Ford motor CO. Could not provide me with infromation regarding if this was a common occurance for this vehicle.

See all problems of the 1997 Ford Explorer 🔎.

The seals that are being replaced have been re-designed and are not covered under any extended service plan (even the "premiumcare").

See all problems of the 1996 Ford Explorer 🔎.

Some 1998/1999 Explorer/mountaineer 4x4 vehicles may exhibit a high pitched squeal/whistle type noise from the front end at speeds from 10mph to 40mph. This noise may be coming from the front half axle shaft excluder(dust) seals (3k070) as they rotate against the inner front hubs. Perform procedures 205-04-9 through 205-04-8 of the 1999 Explorer/mountaneer workshop manual applying a 1/8 thick bead of high tempature wheel bearing grease (part# e8tz-19590-a) onto the seal lips and the surfaces, they contact. Perform procedure 205-04-8 of the 1999 Explorer/mountaineer workshop manual. This is a temporary fix and Ford engineers are currently investigating this issue.

See all problems of the 1998 Ford Explorer 🔎.

Rubber sealing for junction draft shaft and transmission failed. Yh.

Oil is leaking from the front axle seal unto the power steering belt, causing it to slip resulting in loss of power steering control. Please give any further details.

Pinion seal leaking.

The front end noise persists even after both front hubs and front seals were replaced during two seperate service calls. The wiper sensor/motor was replaced before windshield wipers started coming on without warning since the dealer told me that would happen. . The dealer has been very helpful and upfront, but the front end noise still persists and it is quite annoying to have to keep going back for the same symptoms. I have heard this has been a common complaint in this area.

Consumer noticed oil leaking, took vehicle to dealer, dealer stated that seals were defective.