NHTSA Complaint #10147744 — 2002 FORD EXPLORER

DRIVETRAIN PROBLEMS (REAR DIFFERENTIAL, FRONT DRIVESHAFT, TRANSFER CASE). 1. REAR DIFFERENTIAL MAKING WHINING NOISE. THIS WAS WORKED ON TWICE WITH THE PINION BEARINGS REPLACED. DIFFERENTIAL STILL MAKING WHINING NOISE AT FIRST BETWEEN 55-60 MPH AND NOW IS MAKING THIS NOISE ANYWHERE FROM 45 - 70 MPH. VEHICLE WAS REFERRED TO LOCAL FORD DEALERSHIP. WAS TOLD THAT THE PINION RING GEAR NEEDED REPLACEMENT. HAVE FORD EXTENDED WARRANTY FOR POWERTRAIN, BUT FORD WILL NOT REPLACE PARTS UNTIL THEY COMPLETELY FAIL. THEY ALSO CONSIDER THIS A UPDATE WHICH THEY WILL NOT FIX UNDER A RECALL. 2. FRONT DRIVESHAFT CAUSING VIBRATION IN FRONT AT SPEEDS AROUND 65-70 MPH. FORD CONSIDERS THIS AN UPDATE AND WILL NOT REPAIR UNDER EXTENDED WARRANTY UNTIL IT COMPLETELY FAILS. 3. TRANSFER CASE. FORD MECHANIC NOTED THAT HE HEARD A CLUNKING NOISE WHEN SHIFTING TRANSMISSION FROM PARK TO REVERSE. FORD HAS A TSB ON THIS, TO UPDATE THE FLANGE ON THE REAR OF THE TRANSFER CASE. FORD CONSIDERS THIS AN UPDATE AND WILL NOT FIX IT UNTIL IT COMPLETELY FAILS. THE TRANSFER CASE WOULD NEED TO BE DRAINED, REFILLED, AND THEN REPROGRAMMED AGAIN. ALL THESE THINGS ARE LISTED AS COVERED ITEMS IN MY FORD EXTENDED WARRANTY (POWERTRAIN), BUT FORD WILL NOT COVER THEM SINCE THEY CONSIDER THEM UPDATES. THEY WANT ME TO FIT THE BILL OF THE AMOUNT OF $2400 THIS IS HOW FORD IS GETTING BY FROM ISSUING A RECALL. I HAVE NOTIFIED MY WV ATTORNEY GENERAL OFFICE, WHO TRIED WORKING OUT SOMETHING. THAT IS HOW I RECEIVED THE FORD EXTENDED WARRANTY. THEY COULD NOT GET ANY RESULTS, SO ASKED ME TO CONTACT A LAWYER AND TAKE THEM TO SMALL CLAIMS COURT. *JB