Two problems related to axle assembly have been reported for the 2001 Ford Explorer Sport. The most recently reported issues are listed below.
Sport track has 76,000 miles and suddenly started making a roaring sound in the rear which gets louder as speed increases. It was looked at by two companies, both of which diagnosed it as a rear axle problem-possibly a differential breakage. There are slithers of metal on some of the axle parts. When lubrication was checked foaming was detected. I don't have a clue what this means---but I was referred to the dealer or Ford as it was too big a job for the repair shop. I was told to expect a costly repair bill! we have not taken long trips, hauled/pulled anything. I've filed a complaint with Ford regarding this.
During the manufacture of the rear end by Ford they pack the inappropriate amount of grease in the differential (wheather too small or too much) which causes the bearings to rub and wear out quickley. If the problem is not taken care of it can result in a locking of the rear end thus hence the likely hood of accident potential. Just imagine our children being affected. Ford refuses to cause this problem even when it is very clear of liablity. The dealers refuse to fix the issue without a charge and unwarrented extra work and charge. Dt.