Differential Unit Problems of Ford Freestyle

2005 Ford Freestyle has "awd malfunction" message (Ford diagnostic code: p1889). Malfunction message comes on sporadically. No clear reason for the malfunction. Happens while driving or idling. When this happens the vehicle reverts to 2wd. This can be dangerous while driving (especially in wet, snowy, icy conditions) and happens unexpectedly. Have taken vehicle to Ford dealer, with no success in fixing. The dealer followed what Ford says to do according to the code and can't fix problem. Dealer has replaced oil pressure and temp sensor with no change in issue. Now wants to try to change the traction coupler at the rear differential without any guarantee that will wok either. Ford does not have a clear fix for issue and will not cover costs of repairs for awd defect.

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12/10/09 mileage: 35,621 dealer service for rattling noise in engine on cold start up, diagnosed as defective tensioner assembly, but was likely the transmission as same noise was later heard when the transmission was repaired 12/08/11 mileage: 53,401 dealer service for noise in engine at idle - much worse when cold, diagnosed as faulty automatic transmission. Dealer removed and attempted to repair automatic transmission and found input shaft bearing scores and input shaft scored. Differential shaft splines worn down and splines on ptu worn down and seized together. Transmission was then replaced with rebuilt unit. This was the second transmission installed in this car 3/28/12 mileage: 55,234 dealer service for excessive noise in transmission, described as a growl. Diagnosed transmission concern and noise was verified. Were asked to return unit to dealer at later time for further diagnosis 4/2/12 mileage: 55,338 dealer service for transmission problem, corrected by installing a rebuilt transmission. This was the third transmission installed in this car. Dealer explained that the replacement rebuilt transmission carried a one year warranty 7/1/13 mileage: 63,301 while driving on a street, vehicle produced loud clunk sound after which it would no longer respond to throttle inputs. Vehicle coasted to stop. Fortunately, street was empty. Transmission was inoperable, as vehicle would not move forward or backward in any gear under its power. Vehicle coasted in any gear, indicating that final drive line was no longer connected to transmission or engine. Vehicle towed to dealer. Diagnosed failed transmission. Dealer stated that a 4th transmission and replacement oil cooler were needed for $6,900. During the diagnosis, front wheels locked up rendering it impossible to move the vehicle and dealership had to drag it out of service bay.

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On Sunday, may 18, 2008, at approximately 11:15 am, my wife was driving my two (2) children to the mall which is located approximately six (6) miles from my residence. My wife related approximately one and a half miles from the mall she felt a pull in the front end of the car and then heard a loud explosion. She attempted to move the car to the side of the road to no avail. The car was then pushed off the roadway. After moving the car a few metal parts were secured from the road surface. I discovered that the transmission had sustained a catastrophic failure. The back of the transmission is missing as well as the parts contained within. The damage to this unit appears to be consistent with damage caused by a detonation. My wife related there were no warning lights, noises or mechanical failures of the vehicle before this incident occurred. I reported this matter to the dealership where the car was purchased. They seemed to show some level of concern after seeing the failed parts and offered to tow the vehicle to their service department free of charge. Ford later acknowledged the damage was caused by a failure of the differential. This incident occurred in a rural area. Based upon the amount of material which blasted from the transmission, had this incident occurred in town there would have been significant damage to surrounding structures, property, and persons. In closing, the Ford corp. Has offered to pay only half of the cost at $2,100. 00 to repair the damage. In my opinion this is an admission of guilt as I did not ask for any assistance, it was volunteered. I counter offered to pay only the labor costs and requested an answer by cob Friday, may 23, 2008. It is not surprising Ford failed to respond. Accordingly, I am submitting this complaint and request a recall of these transmissions due to the risk of public safety.

Have been experiencing the awd malfunction message and traction control light coming on. Had it in to be looked at. Dealer replaced the pump pressure sensor. The problem went away for a few months but has returned. Dealer again replaced the pump pressure sensor. My wife got 5 minutes from the dealer and the messages reappeared. Dealer now says the rear differential oil pump needs to be replaced. I just spent 2 hours reading from other freesytle owners who have been through the same thing. Ford doesn't specify that the rear differential oil should be changed at any certain mileage, but from what I have read this is what causes the pump to fail. Furthermore, when this pump goes bad it causes the computer to mess up preventing the alternator from re-charging. My wife barely made it to work before the care shut down. If it would have happened on the interstate during rush hour I'd be typing this from the hospital. Please look into this as I"m no the only Freestyle owner to have the same problems. . Read more...