NHTSA Complaint #10133133 — 2002 FORD EXPLORER

ABS LIGHT CAME ON AT 19,518 MILES, 22,071 MILES, AND 27,078 MILES. MORE IMPORTANTLY, HOWEVER, ARE MY ISSUES WITH THE 2002 EXPLORER REAR END. 10/1/03: 27,078 MILES ABS LIGHT CAME ON, THE DEALER REPLACED THE ASSEMBLY. REAR DIFFERENTIAL WAS LEAKING, DEALER REPLACED THE SEALS. 7/28/04: 40,541 MILES REAR END LEAKING AGAIN. HALF SHAFTS WERE WORN. REAR LOCKING DIFF WAS SLIPPING. THE DEALER HAD TO REPLACE BOTH HALFSHAFTS, SEALS, AND CLUTCH PACKS. 9/22/04: 43,203 MILES REAR AXLE CHATTERING. REPLACED WHOLE REAR AXLE ASSEMBLY. 2/25/05: 54,960 MILES REAR DIFF MAKING MORE NOISE. LEFT REAR AXLE BEARING WAS NOISY. REPLACED LEFT REAR AXLE HUB AND ASSEMBLY. ON TEST DRIVE, THE DEALER FOUND THAT THE BEARING THEY JUST INSTALLED WAS BAD, SO THEY HAD TO REPLACE IT AGAIN. 8/11/05: 68,000 MILES LEAKING FLUID FROM REAR END. THE DEALER PERFORMED THE FOLLOWING MAINTENANCE: REPLACED DIFF SEALS, REPLACED TIMING CHAIN, REPLACED RIGHT FRONT HUB ASSEMBLY, REPLACED RING AND PINION, REPLACED FRONT END TIE RODS, REPLACED BOTH LOWER BALL JOINTS, PERFORMED FRONT END ALIGNMENT. ALL TOLD, I HAVE HAD MY EXPLORER IN THE SHOP AT LEAST 10 TIMES. MY WARRANTY IS ABOUT TO EXPIRE (7,000 MORE MILES) AND I'M GOING TO TRY TO GET FORD TO BUY THE VEHICLE BACK. FROM WHAT I'VE HEARD, THIS IS NOT AN EASY PROCESS AND APPARENTLY DOESN'T HAPPEN OFTEN WITH SUCH 'HIGH MILEAGE' VEHICLES. IF THEY DON'T BUY IT BACK I WILL BE FORCED TO TAKE A HUGE LOSS ON THE VEHICLE. I WILL THEN PURCHASE ANYTHING BUT A FORD. *JB