NHTSA Complaint #11666156 — 2020 FORD EXPLORER

On May 14, 2025, at approximately 72,000 miles, the vehicle began making a loud rumbling noise when put into gear and proceeding in forward or reverse. The rumbling\shaking would happen to a lesser degree if torque was maintained in the system and all turns were made while accelerating. The vehicle was immediately taken to the Ford Dealership. The transmission tech began to back up the vehicle, at which point the rumbling\shaking occurred and the tech stated that the rear differential (RDU) had failed. The vehicle was left at the Ford Dealership awaiting complete diagnosis. The vehicle was previously taken to the dealership on October 8, 2024, October 14, 2024, October 24, 2024, November 19, 2024, and December 16, 2024 to have the rumbling\jerking\slipping issues fixed and the complete drivetrain evaluated. On May 30, 3025, the owner was advised that the diagnosis was a failed rear differential and a failed transmission. As documented in NHTSA Safety Issue ID# 11655556, both front axles were just fully replaced replaced three times on October 2, 2024 (65,221 miles), October 16, 2024 (65,301 miles), and October 28, 2024 (65,597 miles) September to address issues with severe vibrations and rumbling which occurred when making turns and driving around curves. These severe vibrations and rumblings coupled with rough shifting and a hop\slip of the transmission when approaching 0 mph caused alarm and deep concern to the passengers in the car, so much so that they expressed fear for their safety as the vehicle shook and jerked. The axle replacement on October 28, 2024 included performing TSB 23-2174 to swap axle types completely by removing the Front Axle Disconnect Assembly. The rumbling\clunking\hopping\slipping persisted off and on after the replacement of the axles and transmission (TCM\PCM) reprogramming by the Ford Dealership. There were no warning lights or messages. The passengers were scared to ride in the car and the driver was nervous. Vehicle can be inspected.