So here's the story last summer my wifes 04 Explorer which we purchased new was making a humming noise around 55-60mph. So I take it back to the dealer and they check it out and end up having to rebuild the rearend. At this time the truck had around 10k miles on it.

It dosen't seem to have any problems after that, until about a month ago my wife say's it's humming again around 65-70mph, and an ABS light came on. So I make an appointment and they call the next day and say they been incontact w/ the Tech services. I asked whats going on and they said we deceided to keep the vehicle overnight. I said ok, and told my wife to arrange to get a car from her parents since Ford wouldn't give us a car. Which pissed me off.

So I call yesterday and asked what the heck is going on and they said they have to rebuild the rearend for the second time! I was told the first time that this happened that they've had problems w/ other Explorers in the same manner. We finally got a rental and the ABS light just needed cleared and nothing showed up on that.

So my question is if this thing has to go in again does the Lemon Law go into effect? The truck now has just under 18K miles and I really don't want this crap to happen again espically if the warranty runs out. I can buy an extended warranty for it, but I think Ford should be helping out on that.

I don't know.....just don't want this rearend to go out on my wife while driving down the freeway.

 

I have an 02 Explorer and it has been the biggest piece of junk. The tranny was rebuilt at 17,000 miles, left front wheel bearing at 52,000, 4x4 module at 34,000, seat belt sensor and ABS sensor at 55,000 and few other things.

On the rear end. I have had the rear axle seals on the IRS replaced four times, both sides. It would go a few months and then start leaking around the seals. They would replace them with the "updated" seals and tell all is good. NOPE. Next set. I have had the fourth set in now for about 8 months and no leaks. We'll see. I wonder if the gear oil leaked out and ran low and burned up your gears? I'm a freak about it now and check it about twice a week. My service writer said that they have had a lot of problems keeping axle seals in the new IRS.

The good news is that I get a loaner everytime I have had to take it in. My dealer has like 20 new Taurus' for loaners. You not getting a loaner with the vehicle under warranty is a load of BS. Your Service Department Manager would not like me very well.

TC

 

I did finally get a loaner when they realized the rear was going to have to be rebuilt. On mine they are rebuilding the whole setup in the pumpkin ring&pinion etc.

 

There's a lot of junk gearsets floating around out there that FCSD is trying to pass off as normal. An engineer told me to keep on ordering repair kits and keep on setting them up until we get one that works. Quality is Job None.

 

the more I hear of issues like this, the more I wonder if Ford can ever truly survive. There are many, many Ford owners that are giving Ford one last shot. Guess what? They are blowing that last opportunity.

This is why each year Toyota and Honda gain a little more and GM/Ford slip a little more.

What part of this does Bill not understand?

 

Just curious, is your wife's 04 AWD? I've noticed a hum from our 04' Explorer AWD.

 

Yes it is......w/ the 3.55 rear gears. I found out this is a common problem on all the Explorer's w/ this setup. Ford just keeps rebuilding the rears cause they can't figure out a solution yet.

 

well, heres a list of problems on this Mountaineer I have (2002 AWD V-8)

--2 sets of Axel seals
--1 tranny rebuilt, 1 brand new tranny
--rear end rebuilt after the famous hum
--ABS sensor
--4 new wheel bearings needed to be replaced
--3 upper control arms replaced
--Clock spring in steering wheel needed replaced

all this with only 43K on it.... Thank god I have a warranty up until 75K