2002 Ford Explorer Power Train

I HAVE RECEIVED ONLY ONE RECALL NOTICE ON MY 2002 FORD EXPLORER RELATING TO PROBLEMS WITH THE TAILGATE WINDOW. TONIGHT, AFTER EXPERIENCING PROBLEMS THAT CAUSED THE AUTOMATIC TRANSMISSION TO JUMP TO A HIGHER RATE OF A MARKEDLY HIGHER RATE OF REVOLUTION, I WAS INFORMED BY THE DEALERSHIP THAT I HAD TRANSMISSION PROBLEMS. THESE PROBLEMS COST OVER $815 TO REPAIR. THE DEALERSHIP ALSO HAD TO REPLACE A SOLENOID SWITCH ON TWO DIFFERENT OCCASIONS IN THE AUTOMATIC TRANSMISSION. I QUICKLY LOOKED AT THE VEHICLE RECALL DATABASE TO SEE IF OTHERS HAD EXPERIENCED THE PROBLEMS I EXPERIENCED. I WAS SURPRISED TO SEE A LARGE NUMBER OF RECALLS THAT I FAILED TO RECEIVE ANY NOTIFICATION FOR. I AM FILING THIS TO REQUEST: (I) FORD TO REQUIRE DEALERSHIPS TO NOTIFY CONSUMERS PERSONALLY IN WRITING OF RECALLS...IF NHTSA OR THE MANUFACTURER DEEMS AN ISSUE IMPORTANT ENOUGH TO ISSUE A RECALL NOTICE, SHOULDN'T THE DEALER BE REQUIRED TO DELIVER WRITTEN NOTIFICATION TO THE CONSUMER? IT IS AN UNFAIR AND DECEPTIVE TRADE PRACTICE TO DO LESS THAN THIS, ESPECIALLY AFTER THE CONSUMER HAS FAILED TO RECEIVE THE BENEFIT OF HIS OR HER PURCHASE AND MAY BE RISKING OF DANGER TO HIMSELF OR OTHERS; AND II. NHTSA TO INVESTIGATE THE AUTOMATIC TRANSMISSION FAILURES DESCRIBED ABOVE. THE CAR LITERALLY "JUMPS" INTO A MUCH HIGHER RATE OF REVOLUTION AND ACCELERATION REQUIRING THE DRIVER TO IMMEDIATELY HIT THE BRAKES. IT'S TOO DANGEROUS, ESPECIALLY IN CITY TRAFFIC OR IN AREAS WHERE SMALL CHILDREN ARE PLAYING. *JB

TWO INSTANCES OF WHINING NOISE AT 50+ MPH AND FLUID LEAKAGE FROM REAR AXLE SEAL 2002 FORD EXPLORER LIMITED. THE FIRST ONE CAUSED LOSS OF CONTROL WHEN ACCELERATING ON HIGHWAY; RESULTING IN COMING TO REST WITHIN INCHES OF CONCRETE BARRIER AFTER JERKING ACROSS SEVERAL LANES. DIFFICULT TO DETERMINE SINCE REAR TRANSAXLE FLUID LEAKS DOWN DRIVE SHAFT TO BRAKE ASSEMBLY. I ONLY NOTICE BECAUSE I PERFORM A MONTHLY INSPECTION OF THE UNDERCARRIAGE. 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 39000 MILES; SECOND AT 50000 MILES. THESE SEALS SHOULD LAST LONGER. SECOND INSTANCE HAD VIBRATION WHEN ENGAGING THE VEHICLE IN REVERSE AND OUD WHINING NOISE/ VIBRATION FROM REAR; THEN FLUID LEAKAGE. THIS IS A MAJOR SAFETY ISSUE FOR THE FORD EXPLORER. SEVERAL WORK COLLEAGUES HAD THE REAR AXLE SIEZE DUE TO LUBRICANT LOSS WITH SIMILIAR SYMPTOMS, ALMOST CAUSING SERIOUS ACCIDENT. MY DEALER ACKNOWLEDGES (BILL ESTES, BROWNSBURG, IN) 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.

THERE IS A LOUD DRONING SOUND FROM UNDERNEATH THE CAR AND VIBRATIONS IN THE FLOORBOARDS.

2002 FORD EXPLORER, REAR END WHINING, REPLACED FOR THE SECOND TIME. FIRST TIME AT 48K MILES. NOW AGAIN AT 57K. SHOULD BE A RECALL ON THIS ISSUE. *JB

SO I BOUGHT A USED 2002 FORD EXPLORER (V6) AND IMMEDIATELY HAD A LOUD VIBRATION COMING FROM THE REAR END. THE MECHANIC KNEW WHAT IT WAS BEFORE I FINISHED THE FIRST SENTENCE. HE INFORMED ME THAT I WAS HIS FOURTH 02 EXPLORER THIS YEAR FOR THE SAME PROBLEM. HE FURTHER INDICATED THAT, IN HIS OPINION, USING LIGHT WEIGHT ALUMINUM ALLOY FOR THE REAR END WAS A VERY POOR DESIGN CHOICE. THE REPAIRS WERE MADE, AND, JUST OUT OF CURIOSITY, I JUMPED ON THE INTERNET TO SEE IF I WAS THE ONLY ONE WITH THIS PROBLEM. I KEYWORD SEARCHED "2002 FORD EXPLORER" (YEAH, JUST THAT) AND HIT NUMBER ONE WAS A TWO PAGE TIRADE FROM QUITE A FEW OWNERS INDICATING THE SAME PROBLEM. ALSO, EVERY 02 EXPLORER OWNER I KNOW (6 OF EM) SAID THEY HAVE OR HAD THE SAME PROBLEM. HOW IS THERE NOT A RECALL? THAT '!@#$% COST ME 1200 DOLLARS. THAT WAS SIX MONTHS AGO. THERE'S ANOTHER VIBRATION IN THE REAR AGAIN. STATISTICALLY, THIS SURE SEEMS LIKE A COVER-UP BY FORD TO ME. *JB

2002 FORD EXPLORER HAS TRANSMISSION SHIFTING PROBLEMS AND WHINE FROM REAR DIFFERENTIAL. OUT OF FACTORY WARRANTY. DEALER HAS TO REPLACE REAR END AT MY COST. NO WAY A DIFFERENTIAL SHOULD GO OUT AT 48,000 MILES. DO NOT KNOW IF TRANSMISSION PROBLEMS WILL BE SOLVED AT THIS TIME. *JB

2002 FORD EXPLORER XLT 4X4 CONTROL MODULE GOES OUT. THERE ARE HUNDREDS OF POSTS TALKING ABOUT THIS PROBLEM IN FORUMS. THEY REMADE THE PART 3 TIMES BECAUSE THEY KNEW THEY HAD A PROBLEM. I GOT STUCK 2 MILES ON A BEACH WITH MY WIFE AND 2 CHILDREN BECAUSE THE 4 WHEEL DRIVE WOULDN'T KICK IN. THERE IS NO WARNING THAT IT IS BROKE UNTIL YOU TRY TO USE IT. *JB

2002 FORD EXPLORER XLS ORIGINAL OWNER 72,000 MILES. HAVE NOTICED A WHINING HUMMING ,NOISE COMING FROM REAR OF VEHICLE WHILE DRIVING 50-70 MILES PER HOUR. BEEN DOING IT SINCE 30,000 MILES. DEALER SAYS POSSIBLE RIGHT WHEEL BEARING?

2002 FORD EXPLORER XLT TRANSMISSION PROBLEMS. SHIFTING FROM PARK TO REVERSE CAUSES A LOUD CLUNKING NOISE AND THE VEHICLE JERKS FORWARD. THERE IS ALSO A PROBLEM WITH THE TRANSMISSION SHIFTING WHEN DRIVING THE VEHICLE. *TR

DT: THE CALLER SAID VEHICLE HAD PROBLEMS WITH THE TRANSMISSION. IN SEPTEMBER 2002 AT 4775 MILES WHEN TRYING TO ACCELERATE THE VEHICLE MADE NOISE AND WOULD NOT ACCELERATE. IN NOVEMBER 2003 AT 34,114 MILES THE LIGHTS ON THE DASHBOARD CAME ON. SHE COULD SMELL SOMETHING. BOTH TIMES SHE WAS TOLD NOTHING COULD BE FOUND. CURRENTLY, ALL THE LIGHTS ON THE DASHBOARD CAME ON AGAIN. WHILE GETTING ON THE HIGHWAY THE VEHICLE LOST POWER AND WOULD ONLY GO 20 MPH. DEALER TOLD HER THE TRANSMISSION NEEDED TO BE REPLACED, AND THE CALLER WOULD HAVE TO PAY FOR IT. *AK

LOUD HUMMING NOISE COMING FROM READ END ON 2002 FORD EXPLORER AT SPEEDS OF 40+MPH...READ ALOT OF COPLAINTS, SEEMS TO BE A DIFFERENTIAL PROBLEM IN THE 1200-1500 DOLLAR RANGE.

2002 FORD EXPLORER, EDDIE BAUER 4WD 4.0L; 83K MILES, FOR THE SECOND TIME ON VEHICLE HAS REAR AXLE SEAL LEAK. REAR AXLE SEALS AND PINION SEALS REPLACED AT 55K; HUMMING NOISE/WHINE FROM VEHICLE AT CRUISING SPEEDS. MANY SIMILAR PROBLEMS REPORTED ONLINE, AND FORD TSB'S ISSUED, BUT NO RECALLS. SEE, FOR INSTANCE: HTTP://FORUMS.CARREVIEW.COM/SHOWTHREAD.PHP?T=93 FIRST REPAIR WAS OVER $700 AND THIS ONE WILL REQUIRE REAR ASSEMBLY REPLACEMENT, IN EXCESS OF $1200. FIRST REPAIR USED 'UPDATED PARTS' FROM FORD, SUPPOSEDLY DESIGNED TO PREVENT PROBLEM RECURRENCE.

MY FORD EXPLORER REAR AXKE TO DIFF. SEALS ARE LEAKING OIL, AND THE REAR END IS VERY NOISY. FORD PUT NEW SEALS IN AT THE COST OF $340.64 . THE DAY I PICKEDED UP THE VEHICLE THEY WERE STILL LEAKING 30 MILES LATER WITH THE NEW DESIGNED SEALS IN. I PUT THE 2002 EXPLORER BACK IN THE GARAGE TO GET THE SEALS CHANGED 6 DAYS LATER. STHE REAR END IS STILL VERY NOISY, BUT THE SEALS ARE NOT LEAKING FOR THE TIME BEING. I CALLED THE FORD 800 NUMBER TO COMPLAIN AND TRY TO GET MY MONEY BACK WITH NO AVAIL.

MY 2002 FORD EXPLORER APPEARS TO HAVE REAR-END PROBLEMS. HAVE OWNED THE VEHICLE FOR A COUPLE OF YEARS AND IT STARTED OUT WITH A WHINING NOISE IN THE REAR-END AND HAS PROGRESSED TO A HARD SHIFT AND ON OCCASION A CLUNKING WHEN THE VEHICLE SHIFTS AROUND THIRD GEAR.

LOUD NIOSE COMING FROM THE REAR END OF MY 2002 FORD EXPLORER 4X4 THAT HAS NOT BEEN FIXED AFTER REPEATED COMPLAINTS OR TAKEN SERIOUSLY BY THE SERVICE DEPARTMENT AT THE FORD DEALERSHIP IN SIMI VALLEY, CALIFORNIA.

I HAVE A 2002 FORD EXPLORER. FOR THE PAST 2 MONTHS THE OVERDRIVE LIGHT HAS COME ON PERIODICALLY AND BLINKS UNTIL THE VEHICLE IS TURNED OFF. I TOOK IT TO LINDSAY FORD IN WHEATON, MD AND THEY CHARGED ME $180 FOR A DIAGNOSTIC TEST TO DETERMINE THE PROBLEM. THEY CALLED TO TELL ME I NEEDED A NEW TRANSMISSION. MY VEHICLE IS 4 YEARS OLD AND ONLY HAS 63,000 MILES ON IT. I THINK IT'S RIDICULOUS THAT I HAVE TO SPEND ALMOST $3,000 FOR A NEW TRANSMISSION WITH THIS LOW MILEAGE ON MY CAR. THIS SOUNDS LIKE A DEFECTIVE TRANSMISSION TO ME. *NM

DT: THE CONTACT WAS DRIVING THE OWNER'S CAR AND PULLED OVER TO PARK. HE SWITCHED THE CAR INTO DRIVE JUST TO PULL UP A FEW FEET AND THE CAR LEAPED FORWARD. HE HIT THE BRAKE AS HARD AS HE COULD BUT COULD NOT STOP THE CAR, AND HIT THE BUMPER OF THE CAR IN FRONT. THIS HAPPENED ON 8-5-05. THE OWNER OF THE CAR NOR THE CONTACT HAD ANY PRIOR PROBLEMS WITH THE CAR. THE CONTACT STATED HE HAD NO FURTHER PROBLEMS SINCE 8-5-05.*AK

DT: CONTACT STATED 2002, FORD EXPLORER HAS BEEN HAVING SHIFTING PROBLEMS. HE NOTICED THE PROBLEM OCCURRING AT 26,000 MILES . IT WAS SHIFTING VERY HARD. HE WILL BE DRIVING WHEN THE CAR WILL NOT SHIFT INTO SECOND OR THIRD GEARS, IT WILL SLIP INTO NEUTRAL, THE CAR WILL SLOW DOWN IN TRAFFIC AND CAUSE A SAFETY HAZARD. HE HAD THE TRANSMISSION RE PROGRAMMED. IT HELPED IT TWICE; BUT THEN IT STARTED DOING THE SAME THING. THE THIRD TIME THE CONTACT WENT BACK TO DEALER AND THEY WOULD NOT REPROGRAM IT AGAIN. HE THOUGHT THE TRANSMISSION FAILED. SECOND AND THIRD GEARS GEAR WERE NOT SHIFTING PROPERLY. FOUND IDENTICAL PROBLEMS ON THE INTERNET. THERE WAS 62,000 MILES ON THE CAR. IT STARTED HAPPENING AROUND 2003 AND HAS GOTTEN PROGRESSIVELY WORSE.*AK

MY WIFE WAS UNLOADING TWO GRANDSONS FROM OUR 2002 FORD EXPLORER. SHE HAD REMOVED THE YOUNGEST ONE WHEN THE FOUR YEAR OLD GOT INTO THE DRIVER'S SEAT ON HIS KNEES AND PRETENDED TO DRIVE. THE IGINITION WAS OFF AND TRANSMISSION IN PARK. HE PULLED ON THE SHIFT LEVER, THE AUTOMOBILE BEGAN TO ROLL BACKWARDS. MY WIFE OPENED THE DRIVERS DOOR TO STOP THE VEHICLE. IT BEGAN TO ROLL BACKWARDS FASTER AND THE OPEN DOOR STRUCK HER KNOCKING HER TO THE GROUND. THE VEHICLE STRUCK TWO TREES SHHORTLY AFTER THAT CAUSING $5675.77 IN DAMAGES TO THE VEHICLE. I CALLED FORD MOTOR COMPANY 0N AUGUST 5, 2005AND SPOKE TO TIFFANY EXPLAINING THAT THE "BRAKE-SHIFT INTERLOCK' HAD FAILED CAUSING THE INCIDENT DESCRIBED ABOVE. HER QUESTION TO ME WAS, "WHAT DO YOU WANT FORD MOTOR COMPANY TO DO ABOUT THIS." I REPLIED THAT I WANTED COMPENSATION FOR DAMAGES AND THE DEFECT CORRECTED. SHE SAID THAT FORD MOTOR COMPANY WOULD NOT INVESTIGATE THIS DEFECT, NOR MAKE ANY COMPENSATION FOR DAMAGES AND THAT I SHOULD HANDLE EVERYTHING THROUGH MY INSURANCE COMPANY. I CALLED AGAIN ON AUGUST,09,05 AND SPOKE TO DAMIAN WHO GAVE ME THE SAME REPLY AS YIFFANY.*JB

2002 TRANSMISSION FAILURE CAUSING ME TO BUY A NEW TRANSMISSION AT ONLY 45,000 MILES..2002 FORD EXPLORER XLT 2WD 4.0L V6. IT HAS BEEN REBUILT 2 TIMES SINCE I WAS MADE TO BUY A NEW TRANSMISSION. THIS IS TOTALLY UNACCEPTABLE AND THERE ARE OTHERS WITH THE SAME PROBLEMS AT THIS SITE. WE SHOULDN'T BE FORCED TO PAY $4000.00 TO FIX A PROBLEM ON A VEHICLE THAT IS NOWHERE NEAR THE EXPECTED TIMEFRAME FOR THIS SORT OF MALFUNCTION (I.E. 150K TO 200K MILES). HTTP://FORUMS.CARREVIEW.COM/SHOWTHREAD.PHP?T=93&PAGE=2&PP=25. *NM

THE TRANSMISSION ON MY 2002 FORD EXPLORER WITH ONLY 45,000 MILES HAS GONE OUT. I STARTED TO NOTICE PROBLEMS WHEN IT HARD SHIFTED BETWEEN 2ND AND 3RD GEAR. ON NOVEMBER 24, 2005, THE OVERDRIVE OFF LIGHT STARTED FLASHING AND THE VEHICLE NO LONGER SHIFTED INTO 3RD GEAR. AFTER SEVERAL ATTEMPTED TO FIX IT AT THE DEALERSHIP, THEY FINALLY DETERMINED THE PROBLEM HAD TO DO WITH AN ALUMINUM CASE AROUND A STEEL MOVING PART. THE PART IS WEARING AWAY THE ALUMINUM CASE. THIS SHOULDN'T BE HAPPENING AT ONLY 45,000 MILES. THIS WILL COST ME APPROXIMATE $2000 TO FIX. ABSOLUTELY ABSURD! I'VE TALKED TO FORD AND THEY WON'T DO ANYTHING ABOUT IT. MULTIPLE POSTS ON CARREVIEW.COM HAVE THE SAME EXACT PROBLEM WITH THIS MAKE AND MODEL. *JB

I BOUGHT A NEW 2002 FORD EXPLORER XLT. AT 13,743 WORK ORDER WRITES MY COMPLAINTS AS "WHEN GOING FROM PARK TO DRIVE TRANS CLUNKS INTO GEAR AND DELAY UP SHIFT A SLOW SPEEDS". DEALER WROTE ON COMPLETED ORDER FORM "CAUSE: INOP, CORRECTION:REPROGRAM PCM, TECH NOTES:ROADTEST TRANS ENGAGEMENT ARE HARSH INTERMITTENT UPSHIFTS ARE FIRM, REPROGRAM PCM...". AT 16,482 MILES I AGAIN COMPLAINED OF CLUNKING WHEN SHIFTING GEARS. DEALER SAID COULD NOT REPRODUCE. AT 24,613 I COMPLAINED OF TRANS CLUNKING, AND HESITATING BETWEEN SHIFTING, AGAIN DEALER SAID COULD NOT REPRODUCE. AT 35,976 MILES THEY SAID THERE WAS A TRANS PROBLEM AND REHAULED (REBUILT) TRANS. AT 50,295 MILES CAR WAS HESITATING AGAIN BETWEEN SHIFTS AND CLUNKING AGAIN. AT STOPPING THE CAR WOULD JERK HARD. THEY SAID THE TRANS WAS BAD AGAIN AND REHAULED IT AGAIN. AT 52,900 MILES I WAS GOING TO STOP AT A LIGHT, I THOUGHT SOMETHING HAD HAPPENED TO THE BRAKES AS THE CAR WOULD NOT SLOW ANY FURTHER (I WAS AT A LOW SPEED AT THIS TIME) FOR A FEW SECONDS AND THE BRAKE PEDAL WAS SHUTTERING AND GRINDING. I IMMEDIATELY WENT TO THE DEALER. THE BRAKES TWICE MORE THE WAY OVER FELT STRANGE BUT NOT AS MUCH AS THE FIRST TIME. I WOULD STEP ON THE GAS, THE CAR WOULD HESITATE BEFORE GOING FASTER AND THEN WOULD JERK FORWARD. THE RPM NEEDLE DURING THIS TIME WOULD NOT MOVE AND THEN JUMP FORWARD AND THEN JUMP DOWN. THREE TIMES ON THE WAY TO THE DEALER THE CAR WOULD ON IT'S OWN GO SLIGHTLY FASTER WITHOUT ME DEPRESSING THE GAS PEDAL FURTHER. THIS WAS ON SATURDAY AND I TOLD THE PERSON WRITING UP MY PAPER WORK I COULD NOT EXCEPT THAT THEY CAN NOT REPRODUCE THE PROBLEM, I NEED AN ANSWER SINCE THIS IS BEYOND BEING A TIME CONSUMING PROBLEM AND BOTHER INTO A SAFETY ISSUE AND I WILL NOT DRIVE THAT CAR AS IS. SINCE THERE WAS NO SERVICE MANAGER THERE, I RETURNED ON MONDAY TO TALK WITH HIM. HE WAS VERY NICE AND SAID THEY WOULD LOOK INTO IT. BUT AGAIN, I AM WITHOUT MY CAR FOR I DO NOT KNOW HOW LONG. *NM

I AM THE ORIGINAL OWNER OF A 2002 FORD EXPLORER. IT MAKES A HUMMING NOISE WHEN DRIVING AT A SPEED BETWEEN 30 AND 55 MPH; ADDITIONALLY THE DIFFERENTIAL LEAKS AS WELL. THE FORD DEALER TOLD ME IT COSTS AROUND $1,500 TO REPLACE. I HAVE HEARD NUMEROUS COMPLAINTS FOR OTHER EXPLORER OWNERS ON THIS VERY SAME PROBLEM, YET FORD REFUSES TO ADMIT THERE IS ANYTHING WRONG WITH THE PART. I THINK IT IS TIME FOR A RECALL. *JB

2002 EXPLORER, 50,000 MILES LOUD NOISE COMING FROM REAR END (DIFFERENTIAL) AT SPEED ABOVE 40 MPH. FROM INTERNET RESEARCH I'VE READ WHERE MANY OTHERS ARE REPORTING SIMILAR NOISES. DEALER QUOTES $1500-1700 TO REPLACE REAR END. *JB

HELLO, I OWN A 2002 FORD EXPLORE XLT WITH 50,000 MILES V-6. IN THE REAR END OF THE VEHICLE THERE IS A GRINDING NOISE THAT IS IN A RYTHMIC PATTEREN. I HAVE SCHEDULED AN APPOINTMENT NEXT TUESDAY BUT WAS WONDERING IF THERE IS ANY RECALLS THAT I SHOULD KNOW ABOUT. AFTER READING SEVERAL FORMS FROM OTHER FORD EXPLORER OWNERS IT SOUNDS AS IF THERE IS A REOCCOURING PROBLEM.*AK