NHTSA Complaint #10171644 — 2002 FORD EXPLORER

I NOTICED A FLUID LEAK FROM THE REAR AXLE OF MY 2002 FORD EXPLORER AND TOOK IT TO THE DEALER FOR DIAGNOSIS. IT TURNED OUT THAT BOTH THE LEFT AND RIGHT REAR AXLE SEALS HAD FAILED. THE VEHICLE HAD ONLY 75K MILES ON IT WHEN THE LEAK BEGAN. I DOUBLE CHECKED THE RECOMMENDED SERVICE SCHEDULE TO SEE IF I HAD MISSED SOMETHING BUT THEY DO NOT RECOMMEND THAT THE REAR AXLE FLUID BE CHANGED UNTIL 150K MILES. SO THIS IS NOT A CASE OF OWNER NEGLECT. AFTER SOME DISCUSSION AT THE DEALER SERVICE CENTER THEY INFORMED ME THAT THIS REPAIR IS FAIRLY COMMON ON EXPLORERS, MOUNTAINEERS AND AVIATORS AND THAT THE REPAIR KIT HAS A NEWLY DESIGNED SEAL. IF THERE IS A NEWLY DESIGNED SEAL AVAILABLE, THIS STRONGLY SUGGESTS THAT THE ORIGINAL SEALS ARE INSUFFICIENT. THIS IS ALSO PROVEN BY THE FACT THAT BOTH SEALS FAILED, NOT JUST ONE. THE COST OF THE REPAIR WAS QUOTED AT $490 ($380 OF WHICH WAS LABOR COST). THIS IS TOO MUCH TO ASK A CONSUMER TO PAY FOR A PART THAT WAS UNDER DESIGNED AND NOT PROPERLY TESTED PRIOR TO BEING PUT INTO PRODUCTION. THEREFORE, I BELIEVE THESE REAR AXLE SEAL PARTS SHOULD BE RECALLED AND THE OEM SHOULD BE FORCED TO REIMBURSE VEHICLE OWNERS FOR REPAIR COSTS. I ALSO NOTICED THAT THERE ARE TSB'S REGARDING EXPLORER, MOUNTAINEER, AND AVIATOR VEHICLES THAT MAY HAVE BEEN FILLED WITH THE WRONG REAR AXLE FLUID AT TIME OF PRODUCTION BUT HAVE NO WAY TO GET MORE INFORMATION ON THIS TO SEE IF MY VEHICLE IS AFFECTED. I WOULD BE INTERESTED IN ANY INFORMATION NHTSA MAY HAVE. *NM