Differential Unit Problems of Ford Explorer - part 2

Rear end noise on a 2002 Ford Explorer. Possible rear differential.

See all problems of the 2002 Ford Explorer 🔎.

Rear end differential problem on 2002 Ford Explorer.

Transmission failure as well as differential failure on vehicle with less than 90k,car has been dealer serviced, this is one of many complaints on this vehicle. At what point will you initiate an investigation? Ford designed this transmission as a sealed unit. Consumer is unable to check the fluid. Flashing o?d light violent shifting, loss of power in 3rd gear.

Differential went out when driving SUV rear axle grinds chatter.

See all problems of the 2004 Ford Explorer 🔎.

Whine from rear differential, was fixed once by plantation Ford of florida when car was bought used in 2005. Problem is back and was told my mechanic that if not rebuilt it may cause rear end to lockup possibly causing a crash and even death.

Had bought 2002 Explorer used, noticed noise from rear end. Told rear differential needed to be replaced, cost for used $1500. But possibility that used could have same issues as this is a very common problem with 02-04 Explorers. My mechanic does several a month. After visiting numerous web sites and forums on the subject, I have seen that it is a very common problem and there is a very real safety concern as the rear end could seize while driving. I believe the dept of highway safety is wrong in not considering this problem to be a safety issue and I think a recall should be issued based on the very large numbers of vehicles that have the exact same problems. And Ford knows about this problem as they have released service bulletins on the subject they know the problem exists, but they do not issue a recall because they want the owners to pay the extravagant costs of the repairs.

Rear differential drivetrain failure. Vehicle mileage 25,000 miles on odometer. 4 wheel drive vehicle, rear differential whine/hum at highway speed. Ford has a TSB 05-23-3 on rear axle noise repair. Took to haldelman Ford, hamilton n. J. For service/repair. Cost of repair was $3,600. 00.

Whining noise coming from rear differential on 2002 Ford Explorer. It is apparent that the rear differentials on these vehicles are failing and Ford is aware of this but refuses to repair the problem at their expense.

Rear differential gears had whining noise replaced gears three times. . . Still whining. Front hub bearings making grinding noise at 80,000 miles, told they are 1500 to replace, cant afford repair. Told if the bearings fail when driving at highway speeds could be a serious safty issue. Bearing should not need to be replaced at 80k. Have researched on the web and found this to be a pattern on the 2002 Ford Explorers. Something needs to be done on this issue.

The contact owns a 2003 Ford Explorer. While driving 25 mph, the rear end of the vehicle suddenly slumped and the rear driver side tire detached from the vehicle. The wheel, brake, rotor, lower control arm, and axle were damaged. Repairs were made. The current and failure mileages were 50,000. Updated 01/09/08. The dealer replaced brake pads and rear end vibrating. Updated 12/12/07.

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I , along with many other owners have logged complaints referring to a noisy differential on the 2002 Ford Explorer that ultimately results in differential lockup, possibly at highway speed. If you search the complaints associated with the 2002 Ford Explorer rear differential logged on this website you will notice over 50 complaints regarding the premature failure of this unit on these vehicles. In addition Ford has identified the problem and sells updated kits to repair this issue, however owners must pay for this kit and have it installed to repair Ford's defective material and workmanship.

I bought a 2003 Ford Explorer in June of 07 with no problems in sept of 07 I started to experience a load noise coming from the rear of the vehicle sounding like a tire was flat or something was rubbing. I took it into the shop and they told me that the rear diff was out on this and it was going to cost several thousand dollars to fix. I contacted Ford they acknowledge the problem but refused to fix it and said that it was not under warranty so they weren't going to do anything about it. I now sit hear with something that I owe money on and can not afford to fix. I have a wife and a son and this is our only mode of transportation. I am very upset that Ford does not stand behind their products like they should. There are numerous complaints on the internet about the same problem but with no solution.

There has not been any accidents, yet. But the rear differential in the 2002 Ford Explorer will eventually fail causing the rear end to lock up and the vehicle be uncontrollable. Many consumers have had to fix and replace the parts at low mileage and Ford is aware of the problem, but refuses to voluntarily recall the parts. The rear differential seals go bad and cause it to leak. There is then what sounds like road noise consistent with vehicle speed. When the fluid is finally gone, the part will eventually lock up. Ford had been advised by numerous consumers of this problem and knows of the possible problems that could arise, but refuses to take the steps necessary to prevent a major accident from occurring. Please look into this and maybe someone can talk some sense into Ford. Thank you. S.

Complete rear differential failure, complete lockup of wheels, started with whining from rear end on 2002 Ford Explorer 4wd with only 84,000 miles.

Noise and fluid leakage in rear diagnosed by local mechanic as failing wheel bearing and differential seal. Replaced differential seal and one rear wheel bearing at 57,000 miles. At 69,000 replaced one front wheel bearing because of noise. At 80,000 mechanic reported that both rear springs had corroded at their upper ends and cracked through. Both these issues are common on 2002 models based on the number of complaints in the data base.

Purchased used 2002 Ford Explorer from original owner. After inspecting vehicle good, I found that the rear differential was leaking and fluid very dirty; appears to have metal filings. Can hear loud rumble and whine while driving. I unerstand that cost is about $1,600 to repair. I also understand now that this is a serious problem with 2002 and 2003 Ford Explorers, and that Ford is well aware of this. I am concerned for my safety with this type of failure.

2002 Ford Explorer XLT, about 62000 miles. Differential noise started about 2 months ago along with a right axle seal leak. Noise is speed relational, starts at about 30 mph and increases in frequency linearly with speed. Noise level also increases with increasing speed. Differential, although leaking slightly, still makes same noise when topped off with synthetic differential fluid. Through research I have discovered this to be an endemic problem with 2002 and 2003 Explorers with hundreds of occurrences noted in various places on the web. Many mechanics report that if the pinion retaining bolt fails, the differential will lock up both rear wheels simultaneously causing loss of control. I have not read where this has actually happened but the noise is very loud and people riding in my car always notice it. I believe that Ford should step up the plate on this one. I have owned nothing but Fords for many years and I drive an excursion. . Read more...

Rear differential seal bad.

I have taken my Ford Explorer (2004 XLT v8 4wd) to the dealership four times to have the differential fluid that is leaking fixed. I have spent about $800 getting it fixed, not to mention the gas that it takes to get there and back and each time I pull in my driveway and look out to see it still leaking. After the second time that I took my vehicle to the dealership, the service department lady told me that they didn't know why it was leaking and that they were going to have to contact Ford to see if it was a recurring problem--and of course it is---and they had to order a different part (that is still not working) to fix it. Couldn't they have known that in the beginning? now they are telling me that if this doesn't work they are just going to have to replace the axles. I have read on several websites that this is a problem that Ford is not willing to do anything about. I will no longer be a Ford customer due to this. Thank you Ford for wasting my time and my money!.

At 95,000 miles there was a rear end howl at speeds between 50-75 mph. I e-mailed a complaint to Ford motor corp. And asked if they could fix it. They replied that there wasn't anything they could do.

My vehicle has a loud humming noise when accelerating at any speed. The mechanics at the Ford garage say the rear differential needs repairs. I had other work done that day due to the loud road noise. I had a wheel bearing replaced, but still have a lot of noise. They said the repair could wait awhile(their suggestion due to the already large expense) I had this same repair done in 2006 and 2005.

Excessive whine/noise coming from the rear end of the vehicle, at highway speeds.

I first purchased my 2002 Ford Explorer in July of 2004. At that time I had the Ford dealership in swainsboro repair the rear end due to a grinding noise that is emitted when the accelerator is applied. The vehicle had approximately 60,000 miles on it. Now, the vehicle has 105,000 miles and the noise has returned and is worse than ever.

Vibration and grinding at low speed turns. Told by Ford a differential clutch package is needed at a cost of $1,100. Called around to severl different repair shops. Found a Ford dealer to repair for $790 plus tax. Getting the usual 12 month 12,000 mile warranty. Called Ford relations for some relief and they offered none because I am out of warranty. This is clearly a problem experienced by a large number of Explorer owners. Everyone please speak up and post a complaint.

2002 Ford Explorer with 75000 miles. During normal driving began to hear a howling/grinding sound from the rear axle. Seemed to be a rear differential problem that was a very common among 2002-2004 Ford Explorers. No recall has been issued.

2002 Ford Explorer 75000 miles ,has rear end noise when between 55-70 mph.

2002 Ford Explorer rear end whines.

I bought a 2002 Ford Explorer 4x4 new. After 30,000 miles the rear gasket was leaking. Was fixed under warranty. 50,000 miles later it was leaking again. Came to find out it was the seals leaking. After tearing into it needed new gear set, traction clutches and bearing failed. Was this the problem to begin with? why with such a common failure were we, the owners, not notified? there was also slipping and popping noise in the rear.

My problem is with the rear differential as well as the hub bearing assembly in the 2002 Ford Explorer, 60,000 miles on the vehicle. Terrible grinding sound in rear wheels, both rear bearings in wheels were bad, as well as differential noise and leaking of fluid, e no recall on these issues, but I have found thousands of complaints for this same issue. It was a safety violation not to recall these. If the rear wheels lock it would send vehicle into a spin, or travel off the road, why have you not remedied this with Ford? you were taking a great legal risk, by not looking out for the safety of consumers.

2002 Ford Explorer, rear end humming and made a great deal of noise. Mechanic said rear end needed to be replaced. Claimed this was a common problem, where was the recall?? now I am supposed to eat the $3000. 00 to repair, I should have bought the highlander. I tried to support USA and got burned, not again!!.

I have a 2002 Ford Explorer that began making excessive road noise from the rear of the vehicle. My mechanic told me the seals on the differential needed to be replaced. I have become aware that this is a recurring problem with these vehicles.

Rear differential failure.

2002 Ford Explorer xls 4x4 man trans. Rear differential noises. Fluid change did not help.

I purchased a 2003 Ford Explorer XLT. I quickly noticed a noise from the rear of the vehicle when speeds of 55-60 mph were achieved. After bringing the vehicle to the auto repair shop I was told that the rear differential needed to be replaced and that it was not only dangerous to drive but extremely expensive. After some research I have discovered that this is a common issue with the Ford Explorer. Should this type of repair that could result in human injury, be addressed by Ford. I am hopeful that your answer will be yes!.

Explorer xl, v6, automatic transmission, with 88,000 miles. Differential problem. Our mechanic determined that the bolt broke on a piece of metal holding the pinion in place. We were going down the interstate, 70 mph, the speed limit. All of a sudden we heard a noise. The sound resembled a flat tire. We pulled off on the shoulder and looked at all 4 tires. No flat. We then called aaa to tow to our first mechanic. He looked and discovered our parking brake shoe, yes, parking brake shoe, had fallen off. He replaced it, $130. He drove it out, and still heard the noise. He suspected the rear end. He couldn't fix that type of problem. We took it to our second mechanic. It took a week to get the lengthy repair done, to get it to fit into his schedule. After the repair was done, ($885) the abs brake system kicked in whenever we stopped. The pedal thumped!so we took it back and he said when the pinion was damaged, that also ruined the speed sensor in the rear end. He fixed it for free, feeling sorry for us that we had two expensive car repairs on our Ford within 2 days. The mechanic said if we had driven much longer with that problem, the car could have seized (my words), and "thrown us through the windshield. " (yes, we wear seat belts. ).