NHTSA Complaint #10154912 — 2004 FORD EXPLORER

REPEATED REAR END HOUSING FAILURES. JAN 06 VEHICLE WAS TAKEN TO THE DEALERSHIP FOR WHINING IN REAR END, "CLUNK" NOISE WHEN SHIFTING TO REVERSE, HESITANT TRANSMISSION, AND HARD TO SHIFT BETWEEN DRIVE, PARK AND REVERSE. REAR END FROM FACTORY WAS FOUND TO BE EXTENSIVELY DAMAGED AND CRACKED DUE TO BROKEN CLIP PRESENT IN REAR END FOUND WHEN IT WAS BEING REMOVED. REAR END WAS REPLACED FOR WHINING NOISE. 2 WEEKS LATER, CAR WAS TAKEN BACK TO DEALERSHIP BECAUSE IT WAS LEAKING REAR END GEAR OIL. I WAS TOLD THIS WAS OVERRUN AND WAS OK. 4 WEEKS LATER THE REAR END OIL PUDDLED IN MY GARAGE AND THE VEHICLE WAS TOWED TO THE DEALERSHIP. ONCE AGAIN THE WHOLE REAR END HOUSING WAS REPLACED. WE I PICKED UP THE VEHICLE AFTER OVER 3 WEEKS IN THE REPAIR SHOP, I ONLY DROVE 24 MILES AND THE REAR END BEGAN TO LEAK GEAR OIL AGAIN. ALSO THE MUFFLER WAS CHERRY RED AND EXTREMELY HOT WHEN THE CAR WAS RETURNED TO THE DEALERSHIP LAST WEEK. THE TECHNICIANS WERE PUZZLED DUE TO THE FACT THAT THE CATALYTIC CONVERTER WAS COOL, BUT THE MUFFLER BURNING HOT WITH CHARRED SPOTS PRESENT. THE TRANSMISSION HAS ALSO BEEN A PROBLEM, ESPECIALLY IN REVERSE. THE TRANSMISSION HESITATES WHEN ENGAGES AND CLUNKS INTO GEAR. THE SOLENOID WAS REPLACED TO FIX THIS PROBLEM BUT THE CAR HAS NOT BEEN OUT OF THE REPAIR SHOP LONG ENOUGH TO SEE IF THE TRANSMISSION IS FIXED. THIS VEHICLE HAS BEEN IN THE REPAIR SHOP 37 DAYS SINCE JAN 1 2006. AT THIS POINT, THE REAR END COULD LOCK UP DUE TO CONSTANT LEAKING OF OIL AND THE EXTREMELY HOT MUFFLER POSED A SUBSTANTIAL FIRE HAZARD. *NM