I just turned 20,000 miles on my 05 Explorer, and have just started to hear the dreaded axle whine when you accelerate above 55 mph and it disapears around 60-65 mph. I took it to the ford dealer, who verified the noise, and is replacing the differential according to the latest TSB on this issue. After reading all the issues on the differential replacements posed on this site, the question I have, is the latest TSB the final fix, or is there still an issue with the differential?

My lease runs out next year and my intent was to buy out the truck at the end of the lease. If there are still issues with the differential, I may have to rethink that plan.

 

The noise is more than likely the ring and pinion not being shimmed properly. The whine while annoying will not hurt anything. Performance cars see this all the time when the backlash is not set properly during a ring and pinion swap. Once the pattern is in the teeth and the wine starts there is nothing you can do to quiet the whine except replace the ring and pinion.

 

JasonGT06, thanks.

 

Like jason said, if you intend on fixing the whine and the problem is due to the gears not being set up properly from the get go, you will need to buy a new ring/pinion gear. It wouldn't hurt to replace all of the bearings/races/seals and rebuild the trak-loc if so equipped.

 

Ford will do repairs under warrenty this week in accordance with TSB 05-23-3. This TSB references a repair kit with new bearings, seals, & gear set. What I was curious about, was all the people that posted they had the repair done and would get the whine back again after a few hundred or thousand miles. Granted these were for 2002 -2004 Explorers with earlier TSBs, but I am still concered. Also I have a open differential because of the traction control and RSC, so the trak-loc is not an issue.

 

Ya know, I think I've read fewer posts by people having the noise return after repair than by people having the noise in the first place. But there are definately some folks unlucky enough to get it back again. I'd ask the service writer how many times he has had repeat complaints after doing the TSB repair. Why don't you bump this thread in 3 or 4 months and let us know how it goes for you. Good luck.

 

Will ford warrant the tsb if a the truck is out of warranty?

 

Rwing21 I do not know. From past experience it will depend on the dealer. Since this is a TSB and not a recal, if the truck is out of warrenty, Ford is not obligated to fix it for free. This stinks because of the number of failures reported, but there is not much you can do about it other then to haggle with your dealer. Hope this helps.

rrgone, I will post a report in a few months. So far I have put 1,000 miles on the new axle diff and knock on wood it is quiet. From what I have seen on this site regarding this issue, there seems to have been 2-3 "repairs" of this problem since the 2002 model came out. The latest one came out in 2005 and the problems seem to have stopped appearing on this site, or at least in a reduced format. So I am hoping this is it. I really like the truck, and would like to keep it, but if the noise comes back in Aug when I have to decide to buyout the lease or give it back, it will go back and maybe I will look at something else unless Ford is willing to give me a real good deal on something.

 

Headed to the dealership this morning... will keep you posted.

 

I have an 02. I have had problems with rearend noise and rear seals leaking. The dealer replaced seals at least 4 times and replaced bearings and seals 3 times and the whole thing replaced at about 20000 miles. the bearings were replaced just before my extended warranty went out at 70000 and it started whining again about 600 miles later. it seems worse between 50 mph and 60. I guess as long as it doesnt leak and dosnt get any louder I will live with it.

 

I traded my Explorer in. The dealership was not willing to fix the seals or give me a discount. The transmission stated shifting erraticaly last week as well.

Too many issues and I cannot take the chance of the rear end or the tranny going out. We now have a 07 F150 XLT that hopefully is in it for the long haul.

Ford better make some changes in the Explorer lineup. My dad has an 07 Explorer Eddie Bauer edition and he has already had to have a cylinder head replaced due to a valve issue.

 

Head replacement? Wow. Did he have the 4.6 or the 4.0 in the truck?

 

shill (shıl) Slang. n. 1. One who poses as a satisfied customer or an enthusiastic gambler to dupe bystanders into participating in a swindle.

Whats that all about?

Back to the thread,,I'm really gonna make sure I get an ext warr on my 05.

Dick

 

We had a 04 Explorer and had it in the shop for that fix and the noise had come back after a few thousand miles.

Notice I said we HAD as we traded that in on a 08 Expedition.

I would not recommend purchasing that vehicle if you can get out from under it.

Tmod

 

4.6 at 17000
Something about valve allignment I think. I will have to check on that. Just spoke with him on the phone and he is now having issues with the transmission down shifting very harsh when coming to a stop. Back to the shop it goes. 18500 miles.