Transfer Case Problems of Ford Explorer - part 2

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.

See all problems of the 2002 Ford Explorer 🔎.

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.

4x4 fails to activate leaving vehicle impaired in 2 wheel mode during critical driving times. Switch on dash goes out, appears to be failure of 4x4 control module and transfer motor. Problem occurs after battery has been disconnected. Repair for vehicle requires changing out control module or transfer case motor. Problem appears to occur in all models of Ford Explorer 1991 - to date.

See all problems of the 1996 Ford Explorer 🔎.

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 bought a 2006 Ford XLT Explorer with apx. 17,000 miles. I had it for about 3 months it had about 19,000 miles. I drive it about 100 miles to a convention and by the time I got there and pulled into a parking lot the vehicle started shifting hard, jerking and lunging. It was making a loud banging sound and felt like the transmission was going to fall out. I took it to Ford, they did some work on the transfer case and replaced a module. About a month and a thousand miles later, it started doing it again. Took it back to Ford and they did some more work. The shifter lever was replaced. Later it started doing it again. I have taken it back several times and the vehicle continues to have the problem. It doesn't do it every day but does do it several times a week, some days are worse than others. As time goes by it seems to get worse and happen more often. Sometime when I put the vehicle in reverse there is a delay to engage and one morning it cause me to back into another vehicle. It also has a cracked running board.

See all problems of the 2006 Ford Explorer 🔎.

The transfer case failed on our 2003 Ford Explorer. This is a known problem at Ford and due to a design flaw with the Explorer. It cost $2,000 to fix. Our mechanic referred us to a transmission/transfer case specialist who had seen multiple Explorers with this problem. Ford should issue a recall for this known defect. The consequences of a failure in the transfer case can be a complete shredding of the gears and sudden loss of power, which could be extremely dangerous.

See all problems of the 2003 Ford Explorer 🔎.

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 owns a 2003 Ford Explorer. The contact stated that she heard a clicking sound during deceleration. A mechanic diagnosed the cause of failure as a worn out range hub in the transfer case. The contact stated that she could never get out of 4 wheel drive, which burns more gas and activates components that are unnecessary during normal driving. The current mileage is 73,000 and failure mileage was 70,000. Updated 02-01-08.

At sharp turns either to the left of the the right, the auto 4x4 enagages and you feel a large shutter. I was fixed by the dealer(they reprogramed the 4x4 permiters) 4 months later if has came back. Nothing has seemed to fix it, many similar situations like mine on the internet.

: 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.

I have a 2003 Ford Explorer XLT 4x4, I have had nothing but problems with it, a few months ago I took it to the dealership because the abs light was on and the 4x4 was not working properly, they supposedly fixed it and told us they replaced a speed sensor, they also found 2 rear axle seal leaks and supposedly fixed those, then in October of '05 I took it in to the dealership because it was jerking between 30 and 40 mph and upon acceleration on hills not mention that I could hear something happening underneath my vehicle, they put it up on the rack and came back out and said the clutch in the rear end was scorched and needed to have the whole rear end replace, so I did but when I was driving it back home after the repair it started jerking again, and after several weeks of worry and wonder another dealership tells me that the transfer case is bad, my Explorer is trying to engage itself in 4x4, so now I am having the transfer case replaced! my Explorer has 41,000 on it right now and Ford has not been much of a help, I have to pay $1500 for the transfer case, I will never buy another Ford product, I will buy a foreign car. Ford really needs to look into all of the complaints and technical service bulletins on these vehicles and I will do anything I can to promote that.

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?.

Clutch in transfer case defective. Causes vehicle to shift into 4 wheel drive unexpectedly.

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.

The vehicle continued to go into 4- wheel drive on its own. The vehicle accelerated, then stalled. The mechanic was unable to duplicate the problem. There were several times when the vehicle was placed in reverse or forward the vehicle would buck.

See all problems of the 2004 Ford Explorer 🔎.

1997 Ford Explorer. The consumer states the four wheel/ two wheel lights are flashing on and off. This will happen until the vehicle is turned off. The vehicle automatically engages into four wheel drive. The only way one can tell this has happened is from the popping and cracking noises coming from the vehicle. The vehicle was taken to cumberland falls Ford twice. They have not been able to diagnose the problem. The vehicle was also taken to a local mechanic, they thought it was the switch. The transfer switch was replaced, but the problem recurred. The vehicle automatically slows down when it goes into four wheel drive.

See all problems of the 1997 Ford Explorer 🔎.

Re:Ford Explorer wheel lockup and uncontrolled skid at highway speed. The vehicle was taken to be repaired. The technician found significant metal fragments in the transfer case indicating severe gear stress when the vehicle self shifted into 4x4 low engagement.

See all problems of the 1998 Ford Explorer 🔎.

On the evening of June 7, 2004, as I was driving on 85s, my car began shaking violently. As I was trying to get out of the way of the traffic, there was a huge boom from my vehicle and the car stopped. Initially, all of the service people around thought that it was my transmission that fell out. I had the car towed to my mechanic who later confirmed that it was my transfer case that had fallen from the bottom of the car. There was absolutely no prior warnings (no service lights appeared in the vehicle) of this happening other than a slight shaking in the car a day or two before. My mechanic is in the process of creating an estimate for this work.

See all problems of the 2000 Ford Explorer 🔎.

Vehicle lost power (to accelerate) yesterday after grinding noise from transmission. Coasted into a parking lot, but was unable to move it from there. Continued to grind moving shift lever from any gear into park. Vehicle has less than 60,000 miles on it. Current transmission is a replacement. Previous (original) transmission dropped into neutral and engine revved (w/ loss of power) at inopportune moments- while accelerating or trying to accelerate, while coasting or while at a complete stop. Began complaining about this about a month after purchase, but transmission was not replaced until Jan. 2002. I was given a 12-month warranty on it then, although the vehicle was purchased with the extended warranty, which was supposed to cover everything (bumper to bumper) to 50,000 miles.

When engaging the 4 - wheel drive low the vehicle locked up without warning. As a result, the steering becomes inoperative. The cause has yet to be determined.

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.