2002 FORD EXPLORER Power Traintransfer Case 4 Wheel Drive Problems

2002 FORD EXPLORER XLT 4 WHEEL DRIVE DOES NOT ACTUATE ANYMORE. MECHANIC SAYS IT IS A DEFECTIVE 4X4 CONTROL MODULE. SEEMS TO BE A COMMON PROBLEM WITH FORD. SAFETY ISSUE WHEN EXPECTING TRACTION IN WINTER AND NOT HAVING IT. *TR

I HAVE AN 2002 FORD EXPLORER AND IT ONLY HAS 81,000 MILES AND I HAVE HAD PROBLEMS WITH THE TRANSMISSION SINCE IT HIT 77,000 MILES. IT HAS BEEN IN SHOP, A TRANSMISSION SPECIALIST, AT LEAST 10 TIMES FOR THE SAME PROBLEM. I HAVE HAD THE ENTIRE TRANSMISSION OVERHAULED AND THE SAME PARTS KEEP WEARING DOWN. THIS IS CAUSING THE TRANNY TO SLIP AND SLAM INTO GEAR. I AM NOW TAKING IT BACK INTO THE SHOP AFTER 6 MONTHS. FORD NEEDS TO DO SOMETHING TO HELP THE AMERICAN PEOPLE IF THEY STILL WANT US TO BUY AMERICAN.

CURRENTLY OWN A 2002 EXPLORER XLT WITH ONLY 65K MILES ON IT. THE TRANSMISSION IS IN NEED OF A REBUILD BECAUSE IS SLIP FROM TIME TO TIME. THE REAR DIFFERENTIAL SEALS ARE LEAKING. THE ENTIRE REAR OF THE VEHICLE MAKES A HUMMING NOISE SO I SUSPECT THAT A REAR BEARING IS GOING BAD. NOT TO MENTION THE 4WHEEL DRIVE SYSTEM HAS NOT WORKED SINCE I BOUGHT IT A LITTLE OVER A YEAR AGO. I'VE HAD INTERMITTENT ISSUES WITH THE AIR BAG CONTROL MODULE AND ALSO THE BACKUP ALARM SYSTEM. THERE IS NOTHING BUT POOR WRITE-UPS ABOUT THIS TRUCK ALL OVER THE INTERNET. ALL THE SAME PROBLEMS I'M EXPERIENCING ARE PROBLEMS MANY OTHER DRIVERS HAVE ALSO HAD. *TR

AFTER OWNING FOR A WEEK AND A HALF, HAD TO HAVE THE G EARS IN THE REAR END REPLACED. LATER INFORMED THAT THE TIRES WERE NOT EVENLY WORN WHICH WAS CAUSING THE REAR END TO POP. AFTER REPLACING THE TIRES, THE FOUR WHEEL DRIVE WOULD NOT WORK. THE 4 X 4 MODULE AND THE WIRING NEED TO BE REPLACED, COSTING $1000.00. THAT IS NOT INCLUDING THE DRIVER WINDOW SWITCH NEEDING TO BE REPLACED AS WELL AS THE WINDOW REGULATOR. NOW THERE IS AN ELECTRICAL PROBLEM COMING FROM THE DASH. UNABLE TO FIGURE OUT WHAT IT IS YET. *JB

DRIVE TRAIN PROBLEMS, HOLING NOISE FROM UNDER VEHICLE, REAR DIFFERENTIAL PROBLEMS AND TRANSFER CASE NOISES, ROUGH SHIFTING FROM 2WD TO 4WD. HAVE CHECKED ON LINE FOR A LONG TIME AND HEARD NOTHING BUT THE SAME PROBLEMS, WHY WASN'T ANYTHING DONE TO FORD TO GET THESE THINGS PUT ON A RECALL. WE BUY THEIR PRODUCT AND NOW THEY DIDN'T CARE ABOUT ANY OF OUR PROBLEMS. SOMETHING HAS GOT TO BE DONE.*AK

IN JANUARY, 2006, MY CAR STOPPED DEAD ON THE HIGHWAY. AFTER IT WAS TOWED TO THE DEALERSHIP, WE WERE TOLD THAT A VALVE HAD BROKEN AND HAD BEEN SUCKED INTO THE ENGINE, CAUSING ENGINE FAILURE. OUR ONLY ALTERNATIVE WAS TO HAVE THE ENGINE REPLACED - WHICH WE DID FOR OVER $5000.00. THE FOLLOWING JANUARY, (2007), AFTER THE FIRST MEASURABLE SNOW FALL OF THE YEAR (SINCE OUR ENGINE HAD BEEN REPLACED), THE CAR WENT INTO A HUGE FISHTAIL SKID ON A SNOWY ROAD AND AFTER THE FIRST SKID, WAS CAUGHT BY THE CABLE GUARD RAIL ON THE SIDE OF THE ROAD - CAUSING ANOTHER $5000.00+ REPAIR. WHEN BROUGHT TO THE DEALERSHIP AFTER THE ACCIDENT, WE WERE TOLD THAT THE 4 WHEEL DRIVE ELECTRONIC MONITOR HAD FAILED AND WE HAD NO 4 WHEEL DRIVE. MY CONCERN - BESIDES THE COST AND INCONVENIENCE AND SCARE OF THE ACCIDENT IS THAT THERE WERE NO...

I HAVE A 2002 FORD EXPLORER. WHEN IT STARTED TO GET VERY COLD, MY EXPLORER, THAT I JUST BOUGHT, STARTED TO NOT WANT TO GO INTO GEAR. IT WOULD GRIND AND SLIP. THERE WAS A CLICKING SOUND COMING FROM UNDER THE DASH. IT WAS FROM THE COMPUTER THAT RUNS THE 4 WHEEL DRIVE. THE 4 LOW BUTTON WOULD JUST KICK IN BY ITS SELF. THEN IT WOULD NOT GO INTO GEAR. AFTER A WHILE OF TRYING TO GET IT INTO GEAR IT WOULD GO. IT WOULD ONLY ACT UP WHEN IT WAS VERY COLD OUT (10 TO -5 DEGREES) IT DID THIS TO ME FOR ABOUT A WEEK AND THEN IT JUST STUCK INTO 4 LOW AND NOW WON'T COME OUT. THERE WAS A SMELL THIS LAST TIME OF BURNING ELECTRICAL WIRE AND SMOKE. NOW MY EXPLORER WON'T DRIVE AND HAS A ELECTRICAL SMOKE SMELL STUCK IN IT. I NOW...

MY FOUR WHEEL DRIVE FAILED, WHILE ELECTRONIC LIGHT SHOWED CAR IN 4 WHEEL DRIVE. CAR SLID BACKWARDS INTO A RAVINE. ON SNOWY ROAD. LOCAL FORD DEALER DID NOT KNOW HOW TO FIX IT, BUT PROBLEM WAS EVENTUALLY TRACKED TO A FAULTY ELECTRONIC MODULE THAT FORD KNEW ABOUT. THIS CAUSED THE SOLENOID THAT ENGAGES 4 WHEEL DRIVE TO FAIL/ THIS WAS AN EXTREMELY DANGEROUS SITUATION. I WAS DRIVING OVER A SNOWY MOUNTAIN ROAD PREVIOUS DAY AND COULD HAVE SLIPPED OFF ROAD IF IT FAILED ONE DAY EARLIER. I SEE NUMEROUS EXAMPLES OF THE SAME PROBLEM. WHY DOESN'T FORD RESPOND?

DT*: THE CONTACT STATED WHEN THE VEHICLE WAS STARTED IT WOULD BE IN 4-WHEEL DRIVE HIGH. SOMETIMES WHEN THE VEHICLE WAS BACKED UP AND/OR MAKING RIGHT OR LEFT TURNS THE VEHICLE WOULD GO INTO 4-WHEEL DRIVE HIGH ON ITS OWN. WHILE DRIVING AT VARIOUS SPEEDS THE VEHICLE KICKED INTO 4-WHEEL DRIVE HIGH ON ITS OWN. THE DEALERSHIP HAS NOT BEEN CONTACTED BUT THE CONTACT PLANS TO CALL THEM SOON. THE 4X4 HIGH LIGHT ILLUMINATED EACH TIME.

DT*: THE CONTACT STATED THE TRANSMISSION SLIPPED AT VARIABLE SPEEDS, SOMETIMES NOT ENGAGING THE NEXT HIGHER GEAR OR AT TIMES THE ENGINE WOULD RACE, THEN SLAM INTO GEAR WITH A BANGING NOISE. THE VEHICLE WAS TAKEN TO A SERVICE DEALER WHERE COMPUTER DIAGNOSTICS WOULD NOT RECOGNIZE THE 5TH GEAR IN THE AUTOMATIC TRANSMISSION. THE TRANSFER CASE WAS REBUILT, BUT THE PROBLEM CONTINUED. THE VEHICLE HAS BEEN INSPECTED ON 7 OCCASIONS. THE REAR LIFT GATE WINDOW HINGE WAS REPLACED, BUT CONTINUED TO FALL OUT OF THE HINGE. THE MANUFACTURER WAS NOTIFIED.

MY 2002 FORD EXPLORER WITH ONLY 40,000 ORIGINAL MILES WAS MAKING NOISE WHEN IT WAS GOING UP A HILL OR DURING ACCELERATION. SINCE IT WAS NO LONGER UNDER WARRANTY I TOOK IT TO A TRANSMISSION REPAIR SHOP. IT NEEDED THE TRANSFER CASE TO BE REPLACED WHICH COST ME OVER $1600. *JB

TRANSFER CASE FAILURE. DEALER-TED BRITT, FAIRFAX, VA REFUSES TO COVER UNDER POWER TRAIN WARRANTY. *JB

1.) MY 2002 FORD EXPLORER 4WD TENDS TO SURGE IN 1ST,2ND, AND 3RD GEAR. IT FEELS AS THOUGH THERE SOME SLIPPAGE ISSUES. 2.) NO "FAILURE", YET. 3.) NOTHING HAS BEEN DONE TO FIX THE ISSUE YET. *JB

DT*: THE CONTACT STATED WHILE BACKING OUT OF THE DRIVEWAY THE VEHICLE AUTOMATICALLY ENGAGED INTO 4 WHEEL DRIVE LOW. THE VEHICLE WOULD NOT DISENGAGE, IT WAS PULLED FORWARD AND PARKED. THE CONTACT WAS INSTRUCTED BY THE DEALERSHIP TO SLOWLY DRIVE ONE AND A HALF MILES TO THE SERVICE DEPARTMENT. THE DEALER WAS ABLE TO DISENGAGE THE 4 WHEEL DRIVE LOW HOWEVER; WAS UNABLE TO DUPLICATE THE PROBLEM OF THE 4 WHEEL DRIVE AUTOMATIC ENGAGEMENT. THE MANUFACTURER WAS ALERTED.

DT*: THE CONTACT STATED WHILE DRIVING 15MPH IN SNOW THE VEHICLES FOUR-WHEEL DRIVE WOULD NOT ENGAGE. SEVERAL ATTEMPTS WERE MADE TO ACTIVATE THE FOUR-WHEEL DRIVE WITH NO SUCCESS. THEREFORE, NO REPAIRS HAVE BEEN MADE.

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...

MY COMPLAINT IS IN REGARDS TO THE TRANSFER CASE SELECTION MODULE ON MY 2002 FORD EXPLORER. DEALERSHIP INDICATED THAT THE SELECTION MODULE IS A COMMON PROBLEM, BUT STILL WANT TO CHARGE FULL PRICE FOR A NEW SELECTION MODULE WHEN IT'S JUST A SMALL PLASTIC PIECE INSIDE THE MODULE THAT FAILS. *JB

BOUGHT FORD EXPLORER (2002) USED FROM TOYOTA DEALER. DROVE FINE FOR OVER 6 MONTHS. BEGINNING IN MARCH (2005), UPON ACCELERATION (ESP. ON HILLS), VEHICLE LURCHES/SHUDDERS AS IT GAINS SPEED. HAVE TAKEN IT TO 3 DIFFERENT FORD DEALERS, WITH NO RESOLUTION (INITIALLY SAID THAT MY NEW TIRES WERE 1/4-INCH DIFFERENT IN SIZE...TIRES WERE REPLACED AND PROBLEM CONTINUED). CONTINUOUS LURCHING FINALLY FRIED THE GEM MODULE (AND FRONT/REAR SPEED SENSORS). FORD STILL DID NOT HAVE AN ANSWER. TOOK IT TO REPUTABLE LOCAL MECHANIC WHO DETERMINED THAT IT WAS NOT THE TIRES, NOR SENSORS, BUT A PROBLEM WITH "SLOP" IN THE TRANSFER CASE. THIS SLOP MADE THE 4X4 AUTO SENSE SLIPPAGE AND COMPENSATE, BUT MORE SLOP MEANT MORE SLIPPAGE AND MORE COMPENSATION, HENCE THE REPEATED LURCHING FEELING. GRAPHICAL ELECTRICAL CHART INDICATED THAT 4X4 WAS ENGAGING AND DISENGAGING APPROXIMATELY 40X A SECOND. AFTER-MARKET WARRANTY WOULDN'T COVER REPAIR AT LOCAL MECHANIC, SO BROUGHT CAR TO FORD...

DRIVE TRAIN AND REAR AXLE HAVE PERSISTENT SHUDDER AND BINDING WHEN SHIFTING GEARS 2-3 AND UPON ACCELERATION DEALERSHIP HAS BEEN NOTIFIED AND WILL NOT RESOLVE PROBLEMS THAT HAVE BEEN ID'D W/ SERVICE BULLETINS FOR THE 5355-RW ASSEMBLY AND THE REAR-GEAR LUBRICANT RATIO MIX-UP INTHE SEALED REAR HOUSING EVEN THOUGH THEY HAVE REC'D PROTOCAL FROM MFG. ON THE PROCEDURE AND/OR REPLACEMENT PARTSAS BEING AVAILABLE SINCE MAR 2001 THIS HAS BEEN NOTED IN OTHER COMPLAINTS THAT HAVE RESULTED IN SEVERE DAMAGE DONE TO THE REAR AXLE AND WHEEL COMPONENTS BUT THEY DO NOT SEE THIS AS A PROBLEM WHEN IN FACT IT CAN RESULT IN VEHICLE FAILURETHAT MAY RESULT IN INJURY OR EVEM DEATH. I PERSONALLY SEE THIS AS BLATANT NEGLIGENCE ON THE DEALERAND MFG. PART OF RESOLVING THIS ISSUE. MY EXPLORER EXHIBITED TROUBLE SINCE JULY'04 AND WAS MFGD. IN THE TIME FRAME THAT A DEFECT WAS BROUGHT TO FORD'S ATTENTION IN...

WAS DRIVING ON A HIGHWAY WHEN THE OD LIGHT STARTED FLASHING THEN THE TRANSMISSION FAILED COMPLETELY. HAVING NEW TRANSMISSION INSTALLED. MANY OTHER THINGS HAVE FAILED TOO. THREE WEEKS PRIOR SHIFT LEVER BROKE OFF IN MY HANDS WHEN I SHIFTED FROM PARK TO REVERSE. HAVE CHANGED RIGHT REAR BEARING WHICH "BLEW OUT". THE 4 WHEEL DRIVE QUIT WHILE THE TRUCK WAS STILL UNDER WARRANTY. WHEN I FIRST GOT THE TRUCK AND COMPLAINED TO THE DEALER ABOUT THE WAY THE TRANSMISSION WORKED HE GAVE ME A PRINTOUT FROM FORD STATING THE TRANSMISSION WAS PROGRAMMED TO ADJUST TO THE DRVERS STYLE OF DRIVING.

MY TRANSMISSION SHIFTER HARD A FEW TIMES ( LOUD "CLUNK") FOR SOME TIME NOW. I THEN LOST 4 WHEEL DRIVE. I AM UNABLE TO SELECT HIGH FOUR OR EVEN LOW. THE LOW BUTTON NO LONGER ELUMINATES AND SHIFTS TO LOW. I DISCOVERED I LOST 4X4 MODE WHILE ACCELERATING FROM A STOP IN THE RAIN AND MY REAR WHEELS SPUN WILDLY. I AM OUT OF WARRANTY..WHAT DO I DO. FORD DEFINATELY HAS A PROBLEM WITH THIS THE AUTOMATIC TRANSMISSIONS. I HAVE ABOUT 48.000 MILES ON VEHICLE. IT WAS PURCHASED USED 3 MONTHS AGO.*AK

THE VEHICLE WENT INTO FOUR WHEEL DRIVE ON ITS OWN. THE MANUFACTURER INFORMED THE CONSUMER IT WAS NOT COVERED UNDER WARRANTY. *JB

PURCHASED NEW FORD EXPLORER IN 4/02 IN 12/03 WITH 37100 MILES TRANSFER CASE STARTED GRINDING AND GOING INTO GEAR BECAME DIFFICULT. TRANSFEWR CASE REPLACED, IN 1/04 4X4 COMPUTER MODULE MALFUNTIONED AND WAS REPLACED. IN 4/04 GRINDING FROM REAR DIFFERENTIAL CASE,HAD TO BE REPLACED WITH ALL INTERNAL COMPONENTS.IN 5/04 SENT DETAILED LETTER TO WILLIAM CLAY FORD EXPLAINING DIFFICULTIES WITH VEHICLE ALONG WITH ALL REPAIR BILLS. . ON 5/18/04 GOT A PHONE CALL FROM LYNN ARLEDGE(FORD EXECUTIVE REP). *AK

4X4 LIGHT ON DASH WOULD SPORADICALLY FLASH ON AND THEN GO OFF. DURING A SNOW STORM, FOUR-WHEEL DRIVE FAILED TO WORK, CAUSING THE CAR TO SLIDE ON ROADS. HAD TO BUY SNOW CHAINS TO GET THE CAR TO A DEALER. IT TOOK TWO VISITS BEFORE DEALER COULD DIAGNOSE PROBLEM AND REPLACE A 4X4 ELECTRONIC SHIFT MODULE PART # 2C5Z*7E453*BD.

MY 2002 FORD EXPLORER XLT HAS EXPIERENCED ALL THE POWER TRAIN PROBLEMS THAT I AHVE FOUND ON THIS SITE.MY DEALER AHS BEEN ADMIRABLE IN TRYING TO RESOLVE THESE PROBLEMS BUT IT SEEMS WE GET ONE FIXED AND ANOTHER STARTS.THE FIRS WAS THE TRANSFER CASR HAD A SHUTTER IN IT BETWEEN FIRST AND SECOND GEAR , THEN THE REAR END HAD A BAD BEARING, THEN THE LEFT REAR AXLE HAD A BAD WHEEL BEARING, THEN THE VEHILCE WAS STAYING IN FOUR WHEEL DRIVE ALL THE TIME, THIS HAPPENED ON A TRIP THIS FALL BARE GROUND. THEN THE LATEST IS THE TRANSMISION IS GOING TO NEUTRAL AT STOP SIGNS AND RED LIGHTS BY ITSELF. THE VEHILE THEN SITS AND REVS UNTIL WITH A BANG THE TRANSMISSON ENGAGES AGAIN. *AK

2002 FORD EXPLORER 4X4 STRAINING AND BANGING SOUNDS IN DRIVE TRAIN WHEN IN 4X4 MODE AND WHEN CORNERING IN THIS MODE CAUSES VEHICLE TO BECOME HARD TO STEER AND CAN FEEL VEHICLE SHUDDER AS BANGING OCCURS. WAS TAKEN TO GREINER FORD ON 12/04/03 THE DAY PROBLEM STARTED AND WAS TOLD BY SERVICE ADVISOR JIM FEILER THAT FORD TECHNICAL SUPPORT HAS BEEN ADVISED OF THE PROBLEM AND THAT THEY DO NOTICE ALL SYMPTOMS I BROUGHT VEHICLE IN FOR BUT THEY DO NOT KNOW WHAT THE PROBLEM IS AND THUS ARE NOT AUTHORIZED BY FORD TO REPAIR EVEN THOUGH VEHICLE IS STILL UNDER FULL WARRANTY. I WAS THEN TOLD THEY FEEL VEHICLE IS SAFE TO DRIVE WHICH I FEEL IS INTERESTING SINCE THEY ACKNOWLEDGE THEY UNIT HAS A DRIVE TRAIN PROBLEM BUT DO NOT KNOW EXACTLY WHAT THE PROBLEM IS, SO HOW CAN THEY BE SURE IT IS A SAFE VEHICLE. *LA

IT WAS DURING THE FAST FREEZE WHEN THIS INCIDENT TOOK PLACE. WE WENT FROM 45 DEGREES TO 20 DEGREES WITH IN 2-3 HOURS. IT WAS RAINING AT FIRST THEN SWITCHED TO ICE & SNOW. WE PUT THE 2002 FORD EXPLORER IN 4X4 DRIVE DUE TO THE WEATHER CONDITIONS. AS WE WERE ENTERING THE EXPRESS WAY WE LOSS CONTROL OF THE TRUCK ONLY GOING 28 MILES PER HOUR. WE SPUN OUT OF CONTROL AND HIT THE GUARD RAIL. IT WAS AS THOUGH WE HAD NO 4X4 DRIVE. WE CALLED THE POLICE TO GET A ACCIDENT REPORT FOR OUR INSURANCE. WE THEN TOOK THE TRUCK A WEEK LATER TO MARTIN BUICK TO FIX THE BODY DAMAGE TO THE LEFT SIDE OF THE TRUCK. THEY TOOK THE TRUCK TO LASKO FORD ACROSS THE STREET TO WORK ON THE 4X4 SYSTEM. THEY TOOK THE CLUTCHES OUT AND DRAINED THE TRANSMISSION FLUID. THEY FOUND DAMAGE...

WHILE DRIVING APPROX. 40 MPH, VEHICLE SUDDENLY WENT INTO 4 WHEEL DRIVE LOW RANGE. OCCUPANT WAS WEARING SEAT BELT AND CAR CAME TO AN ABRUPT STOP. ACCIDENT WAS AVOIDED DUE TO LIGHT TRAFFIC THIS DAY. CAR IS @DEALER 4 REPAIR. DEALER CLAIMS COMPUTER THAT SENDS SIGNAL TO 4 WHEEL DRIVE TRANSFER CASE FAILED DUE TO COLD WEATHER AND SENT FAULTY SIGNAL TO ENGAGE 4 WHEEL DRIVE INTO LOW RANGE. TEMP WAS 40 DEG. THAT DAY. I AM CONCERNED ABOUT THE STRESS PUT ON ALL OF THE INTERNAL DRIVE COMPONENTS DUE TO THIS SUDDEN ENGAGEMENT. DEALER SAYS THEY CHECKED FOR OUTSIDE DAMAGE, BUT DAMAGE WILL MOST LIKELY BE INTERNAL I.E. TRANSMISSION, TRANSFER CASE, SHAFTS, ENGINE, DRIVE ASSEMBLYS. THE DAY B4 WE TRAVELED ON THE INTERSTATE AT SPEEDS BETWEEN 60-70 MPH. IF THIS HAD OCCURED AT THIS SPEED IT WOULD HAVE BEEN MUCH WORSE. WIFE WENT FORWARD DURING ENGAGEMENT AND STRAINED HER...