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.
2002 Ford Explorer transmission complaints
Page 45 of 51: complaints 1,301 to 1,330 of 1,502, newest first, as owners wrote them.
Differential failed; repaired under original factory new vehicle warranrty. Differential failed again, 9000 miles later, when vehicle was out of original warranty. Dealer wants $825.00 to replace the exact same parts again in the differential.
Vehicle made increasingly loud noise at right rear wheel area. Sounded like airplane take-off or tunnel sound at rear while driving. Noise increased on wide turning roads as if some kind of pressure exerted on right rear wheel. Thought it might be tire pressure problem. Before having tire checked the vehicle became nearly impossible to drive on a straight-away at 25 MPH with serious noise in the rear that sounded like something would fall apart soon. Fortunately I was very close to a auto service center in a 25 MPH area. Car could no longer be used. The right rear hub bearing assembly was replaced. The other 3 were checked and were fine. I do not have any of the parts.
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
Two instances of whining noise at 50+ MPH and fluid leakage from rear axle seal 2002 ford explorer limited. The first one caused loss of control when accelerating on highway; resulting in coming to rest within inches of concrete barrier after jerking across several lanes. Difficult to determine since rear transaxle fluid leaks down drive shaft to brake assembly. I only notice because I perform a monthly inspection of the undercarriage. Noticed significant corrosion of brake assembly where fluid is running into the wheel assembly. Only when leak is significant will fluid drip onto surface below rear axle. Dealer noted ford engineers are aware of problem but expect the consumer to pay for repairs. First replacement of rear axle seals at 39000 miles; second at 50000 miles. These seals should last longer. Second instance had vibration when engaging the vehicle in reverse and oud whining noise/ vibration from rear; then fluid leakage. This is a major safety issue for the ford explorer. Several work colleagues had the rear axle sieze due to lubricant loss with similiar symptoms, almost causing serious accident. My dealer acknowledges (bill estes, brownsburg, in) that many explorers (2002-2005) have this problem and ford motor company engineers are evaluating; as a dealer there is nothing they can do. Ford has not indicated a fix other than to check fluid level, replace rear axle seals, and/or the rear unit. This is a significant hazard since in most cases the vehicle owner will not know there is a pending failure due to the fluid leaking down the rear axle drive shaft toward the brake/wheel assembly. The whining noise will increase as fluid level decreases with risk failure and loss of control. This problem is far more common than reported due to the difficult nature of observation of leakage. One has to crawl under the rear transaxle and carefully inspect the two axle seals to look for signs of corrosion and fluid leakage.
2002 4x4 explorer limited with v8. At 7390 miles (3/12/03, invoice # w40836) two issues; the transmission never shifted properly and it started leaking fluid everywhere. Two weeks later the dealer admitted they didn''t know the cause and replaced the transmission with a new one. Engine severely overheated (invoice 3w47852). At 20k miles the truck will once in a while stop (as if I hit something) as I start to back out of the garage - problem discovered at 31k brake job - rear shoes on parking brake broke loose on drivers side (both) and only one on passenger side. Loose shoe on pass. Side would wedge with good one and lock up wheels when moving slow. Lot's of arguments and ford finally replaced shoes (4/25/05 invoice # 99323). At 26k (11/05, no invoice) one tire went flat and upon inspection by a tire shop, that tire and a second tire had tread separation - running goodyear''s. Ford quickly replaced both tires without any questions. At 29k, my family and I moved from mi to ga. Each time I stopped for gas the explorer sounded like the front end was grinding metal to metal on the gears. The 4x4 was in auto for the trip and once I got back on the highway above 20 MPH the noise went away. However, it continued to shift poorly and it started to surge (shake) or thump like something was catching in the drive train every time I would let off the gas pedal and allowed the truck to decelerate without braking. Even after new brakes and rotors, the problem got worse and worse - now at 34k, (5/30/05, invoice # w50821) the truck is in the dealership for the 3rd time on this issue. The first time, they replaced the "module-transfer sh" which did pretty much eliminate the shifting issue. They also replace the "drive shaft flange per ssm 16824" whatever that means. But a major problem in the drive train still exists and it still unresolved. Here's my point, ford has a major drive train problem with the redesigned 2002 explorer.
Drive train and rear axle have persistent shudder and binding when shifting gears 2-3 and upon acceleration dealership has been notified and will not resolve problems that have been id'd w/ service bulletins for the 5355-rw assembly and the rear-gear lubricant ratio mix-up inthe sealed rear housing even though they have rec'd protocal from mfg. On the procedure and/or replacement partsas being available since mar 2001 this has been noted in other complaints that have resulted in severe damage done to the rear axle and wheel components but they do not see this as a problem when in fact it can result in vehicle failurethat may result in injury or evem death. I personally see this as blatant negligence on the dealerand mfg. Part of resolving this issue. My explorer exhibited trouble since july'04 and was mfgd. In the time frame that a defect was brought to ford's attention in this matter. What do they want a certain number of deaths or injuries?
Rear end on my 2002 ford explorer is roaring and leaking fluid.
The rear seal on the axle assembly had to be replaced 5 times on the consumers 2002 ford explorer. *jb the consumer requested reimbursement. *sc
My husband and I purchased a 2002 ford explorer xlt around mid july/early august 2002. In august of 2003 I notice that my car was experiencing some clunking in the transmission. I don't know the full detail of that problem but they gave me an extra 5 year warrenty on my vehicle. Last year my family and I took a trip to florida and my car would get this loud roaring sound at 45 miles per hour. When we returned from my trip I called to complain about it. They asked me to bring it to them but they said that it was my tires. My husband replaced the tires hoping that this would resolved the problem. (even before this problem because they requested us too). A week later my husband and I went to texas and the sound got worse. Upon returning from our trip I was told that it was my axel. My family and I could have been killed because of their mistake. I 've had my front and rear wheel bearings, axel, axel boot, hubs bearings, emergency brake (which they say was split) replaced. I still hear a problem with my transmission but they keep telling me that my car is safe to ride in. I do not feel safe in this vehicle. I've gone to the attorney general, filed a complaint for abitration. My (prepaid) attorney has even sent them two letters advicing them to take this situation seriously. They never replied back to me or my attorney. I'm ford plan and I really thought that I would be treated with a little more respect. I want them to be responsible and see that they sold me a "lemon". I really need some help. Thank you.
The "o/d" light of my 2002 ford explorer lit up without warning while I was turning. Engine "revved" but didn't accelerate. Oncoming cars swerved to avoid me. This was an unsafe situation, as I expected the vehicle to function properly. I took the car to the dealer and was told the transmission had to be totally rebuilt, for $2,400, since I was 4000 mi out of warranty, even though <3 years. I asked the service manager if ford would cover it. The zone person, advised no. I phoned customer assistance, and was told there were dealer/field discretionary funds to pay for repairs outside of warranty, but only for "loyal" customers. I was told that I should have purchased the vehicle new and had my maintenance done at the dealer. I asked what maintenance should been done on the transmission. I was told that there was none. I spoke with a gentleman in the quality department at a local transmission plant, who said this was a common failure, but that ford wouldn't offer any help because "money is tight". He said that the bands in my transmission had been superceded twice due to this problem, and a tech bulletin existed, explaining this to dealerships. I read many other complaints on this website! I fail to understand why ford honors a secret warranty for "loyal" customers yet offers no recourse for customers who were put in the same unsafe situation, just because they bought the vehicle used. I had the repair done at an independent repair facility. Ford advises they will not take any financial responsibility because the repair was done at an independent. I am one of many consumers who must drive in a defective and dangerous vehicle, due to this transmission problem. It failed me once without warning, I paid $1,200 for repair, and approach intersections with trepidation due to the possibility of my transmission unexpectedly slipping again. I would welcome contact at 248.808.1279 to discuss resolution of this dangerous issue.
The gear shifter broke off while shifting from park to reverse. The shifter completely snapped off the assembly rendering the 2002 ford explorer completely inoperable. Mileage was only 56,000 miles and been driven for only 4 years. The car has to be towed to the dealer's location. The dealer replaced the steering column assembly (part # fmc4l2z 3c 529 da) at a cost of $706.20 to the vehicle owner.
Dt: problem with back end, took vehicle to the dealer,and dealer said they fixed axle, then, took back vehicle to the dealer, and they fixed hub, and replaced the rear wheel bearings. In last 3 months vehicle has been in shop 3 times. Currently, in the shop. Went to get oil change last friday, and mechanic noticed oil was leaking from the axle. Currently vehicle in shop trying to figure out what was wrong with it. This happened before. They gave consumer an extra 5 yr warranty because of the transmission, and this was 8 months after purchasing the vehicle. Dealership kept saying vehicle was safe even though didn't know what was wrong with it.
Dt: gear shift broke off. Consumer said shifter broke off and landed in his lap. Consumer was shifting into gear when this happened. No previous problems. Vehicle is serviced regularly. Consumer had hightech auto center fix problem, they replaced the whole column. Ford refused to do repairs, said warranty expired.
Dt: consumer states that transmission went from park to drive. While she was at her daughter's school she stepped out of the vehicle to talk to someone and the car jumped from park to drive and hit another vehicle. Also the transmission went out. She had several other problems with this vehicle. She was never notified anything from ford about any type of problem. The service department printed out a tsb for her, including the following numbers; transmission: 03-25-4 dated 12-22-03, and gear selector:04-22-12 dated 11-15-04. The vehicle is regularly maintained.
The consumer experienced a clunking noise which the dealer reported originated from the driveshaft. Some of the drive shaft mounting bolts were missing and some were loose. The dealer repaired the moutning bolts. There was no warning of the driveshaft having missing bolts. *ak *tt the consumer felt that the dealer should have replaced the original bolts that had come loose. The consumer also felt that ford should cover the cost of repairs. *sc
Was driving on a highway when the od light started flashing then the transmission failed completely. Having new transmission installed. Many other things have failed too. Three weeks prior shift lever broke off in my hands when I shifted from park to reverse. Have changed right rear bearing which "blew out". The 4 wheel drive quit while the truck was still under warranty. When I first got the truck and complained to the dealer about the way the transmission worked he gave me a printout from ford stating the transmission was programmed to adjust to the drvers style of driving.
Loud thumping noises coming from front end of 2002 ford explorer. Ford says they are normal. It didn't do this when we bought it. Also there is a loud whining noise coming from the rear end. Rear end has been replaced onced. Problem disappeared for about 10k miles after it was replaced. Wife is afraid to drive the car as we have three newborn babies.
I noticed some vibration/shuttering when accelerating in the rear end of my 2002 explorer in april, 2005. The local dealer's service department diagnosed the problem as needing to replace the clutch pack for the rear axle (which they said would cause shuttering when turning) and to replace the tires. I put new tires on the rear which did nothing for the shuttering and in addition I could now hear a loud humming upon decelaration from speeds over 50 MPH approximately. The dealer's service dept. Rechecked it and told me in addition to the clutch pack, I also needed to replace the ring and pinion at a total cost of over $1,500.00. The odometer reading on the initial service date was 43893 miles (warranty expired at 36000). I subsequently had a independent repair shop look at it and they told me they couldn't find anything wrong with it. I'm not sure what to do as I don't want to have my wife driving a vehicle that is a potential danger, but I don't want to unnecessarily spend $1500.00.
Rear end noise (grinding) in our 2002 ford explorer during de-acceleration. First time to dealer 8/25/03 mileage 30,901, nothing done, 2nd time to dealer for the same problem 11/03/03, mileage 36,930 could not find problem. Problem seems to go away, came back around 75,000 miles. Took vehicle to another dealer and complete rear end was replaced at a cost of $2600.00. Not sure why it was not detected with the first time to the dealer?
There is a whining noise in my 2002 ford explorer coming from the rear differential. I occurs between 40-65 MPH. It quits when I let off the gas. I am worried that the rear differential (the source of the noise) will soon lockup when I am driving on the highway, possibly causing an accident.
4 wheel drive will not engage. Has been used one other time since I purchased the vehicle in 2002
Transmission failed. Had to be replaced. Only 50,300 miles on the vehicle. Service technician advised this is the 5th ford explorer he's had to replace the transmission on this month alone. He said the transmissions on the explorers are failing between 50k and 60k miles.
2002 ford explorer gear shift fell into the consumer's lap while backing out of the driveway. *mr *sc
Dt: transmission will not go into reverse, and there is no neutral. There is only 57,000 miles on the vehicle. The vehicle has had regular maintenance and checkups. Transmission was making clanking noise when put into drive or reverse. Vehicle has been making noise since 2002. It was taken to the dealership, and it was checked. Dealership did not find a problem with the transmission. Vehicle was put in reverse, and it started jumping. Then it went and stopped in reverse. Then, vehicle was put in park and t switched to reverse. There was no reverse. It was put into neutral, and it went forward. When the vehicle was put into drive, it would go forward.
2002 ford explorer experiencing problems with the 4wd, the over drive light illuminates on the dashboard and the vehicle is giving off a rotten egg smell. *mr there were front end problems. The 4wd module wasn't working. The driveshaft and both front wheel bearings were replaced. The rotors were out of round. The service engine light illuminated along with the over drive light. The transmission experienced the same problem on two occasions and possibly a third time. A large puddle of transmission was found under the vehicle. The torque converter was noisy. The acceleration pedal would pull back. When the vehicle was accelerated, it would whine. The left rear wheel bearing was gone and caused damage to the axle, brakes and the tire was barely holding on. The error code for the service engine soon light was due to the solenoid which had been changed before. The A/C was inoperative. *sc
Loud whining noise in the rear differential .. The bearings are bad and the seals are leaking
Vehicle has 78,000 miles, rear axle half shaft seal leaks at differential and there is a loud "whine' or "hum" while accelerating, noise stops when you let off gas. I have read numerous similar complaints and feel this is a manufacters defect.
Driver noticed while shifting the transmission forward or backward the gears are hard and a loud knocking noise started coming from the front. Driver took the vehicle to the dealer, and mechanic determined that the vehicle has to be placed on a diagnostic machine for analysis. *ak this particular problem has been on going since the warranty expired. The gear shifter became stuck in reverse gear unless it was pulled firmly towards the driver. *bf
Transmission and rear-end. Sealed transmission was serviced at dealership at 29,000 miles. Since then transmission has a whirr and then a clunk while decelerating back into first gear. Whining noise from rear-end since 12,000 miles. Ford replaced faulty rear-end seal 6 months ago, whining still there. I feel that ford is stringing me along until warranty expires. Ford knows there are problems but wont fix until part fails completely.
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