NHTSA Complaint #10118200 — 2002 FORD EXPLORER

1. REAR END HOWLING NOISE (3/18/2005) - HEAR NOISE WHEN ACCELERATING BETWEEN 40 AND 65 MPH. WHEN LETTING OFF OF ACCELERATOR, NOISE GOES AWAY, COMES BACK AGAIN WHEN ACCELERATOR IS PUSHED AGAIN. DEALER SERVICE DEPT REPLACED REAR CARRIER BEARINGS, CUP, SEALS, AND SPACER IN REAR DIFFERENTIAL. NOISE NOW OCCURS BETWEEN 65 AND 70 MPH. WAS TAKEN BACK TO DEALER SERVICE DEPT ON 4/11/2005. WAS INFORMED 4/20/2005 THAT REAR DIFFERENTIAL WAS ADJUSTED WITH NEW SPACER, BUT NOISE IS STILL THERE. SERVICE MANAGER HAS ANOTHER FORD EXPLORER ON LOT AND TEST DROVE IT. THIS EXPLORER HAS SAME NOISE BETWEEN 40 AND 65 MPH. ONE OF THE TECHS (WHO USED TO WORK AT A FORD DEALERSHIP) TOLD SERVICE MANAGER THAT ALOT OF 2002 FORD EXPLORER OWNERS HAVE BEEN HAVING THIS PROBLEM. FORD HAS NO SOLUTION OR CURE. 2. NOISE IN TIMING CHAIN AREA. FORD HAS A TSB ON THIS. I CAN HEAR THIS RATTLING NOISE COMING FROM THIS AREA AND TOLD DEALERSHIP TO LOOK INTO IT. THEY COULD NOT DUPLICATE THE NOISE, ALTHOUGH WHEN TEST DRIVING IT WITH ASSIST. SERVICE MANAGER, I COULD STILL HEAR THE NOISE, BUT HE COULD NOT. I HAD MY LOCAL MECHANIC CHECK THIS OUT, AND THEY CAN HEAR THE NOISE THAT I'M TALKING ABOUT. THIS PROBLEM HAS YET TO BE FIXED. 3. VIBRATION COMING FROM FRONT END ON INTERSTATE THAT STARTS AT AROUND 70+ MPH. WHEN CLIMBING A STEEP HILL ON INTERSTATE AND TRANSMISSION DOWNSHIFTS, CAN FEEL A GRINDING NOISE IN POWERTRAIN. DEALER BELIEVES THAT THE FLUID IN THE TRANSFER CASE MIGHT NEED TO BE CHANGED,CAUSING CLUTCHES INSIDE TO STICK. WILL FIND OUT TOMORROW (4/21/2005). *NM