NHTSA Complaint #10155476 — 2002 FORD EXPLORER

THREE INSTANCES OF WHINING NOISE AT 50+ MPH AND FLUID LEAKAGE FROM REAR AXLE SEAL 2002 FORD EXPLORER. THE FIRST ONE CAUSED LOSS OF CONTROL WHEN ACCELERATING ON HIGHWAY. DIFFICULT TO DETERMINE SINCE REAR TRANSAXLE FLUID LEAKS DOWN DRIVE SHAFT TO BRAKE ASSEMBLY. I 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 30000 MILES; SECOND AT 460000 MILES AND THE THIRD AT 62000 MILES. THESE SEALS SHOULD LAST LONGER. SECOND INSTANCE HAD VIBRATION WHEN ENGAGING THE VEHICLE IN REVERSE AND LOUD WHINING NOISE/ VIBRATION FROM REAR; THEN FLUID LEAKAGE. MY DEALER ACKNOWLEDGES 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. *NM