Rear differential = junk
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Rear differential = junk
I am getting a whining noise from the rear diff. From what I've read here, it seems to be a guaranteed issue for the 02-04 explorers. I took a look at the diff. and noticed it was leaking. It jogged my memory about a leak I had about 15k miles ago(when truck was still under warranty). I dug up the service record and low and behold, they had applied TSB 05-23-03. Looks like they did a complete replacement of all bearings, races, ring and pinion gear. They also replaced the front and rear pinion seal and rear axle seals(all were leaking). Well, here we are 15k miles later and the exact same problem is back. Either these rear ends are really bad or the dealership did not do the job correctly. In all fairness, I don't want to go into the dealership with guns a blazing if Ford is supplying them with inferior parts that they have to use. Has anyone had any luck in getting the dealership to "re-fix" this issue under some kind of warranty(free)? I refuse to pay $1200+ to fix an issue that should have been done right the first time.
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Joined: Jul 2005
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i would check the oil level and see if it is low. might be as simple as adding a little more lulbe. also verify that the noise is not a wheel bearing instead of the differential. wheel bearings are not a common problem, but do occure on some trucks at 80K miles.
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is the noise constant from 0 to 60 MPH or does it just start at 60 MPH? does it go away if you back off on the throttle or always noticable. wheel bearings noise is constant. differential gear noise is only noticed at 60 MPH when under load. back off on the throttle and it goes away.
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I removed the fill plug and oil started dripping out...so I'm assuming there is plenty of oil in there. The oil was black, but I'm not sure if that's normal after 15-20K miles. The noise only occurs while accelerating b/w 50-60 mph...not constant. That was actually my original post. 
I stopped by the dealership Friday and they told me I had to contact Ford directly before they would do anything. I'm sure that will be a lost cause. I'm guessing Ford will provide little charity after losing $8 billion in a single quarter. A new rear end every 20K miles is rediculous. I've had the truck in 2 times for a leaking drain plug and it's still leaking.
I stopped by the dealership Friday and they told me I had to contact Ford directly before they would do anything. I'm sure that will be a lost cause. I'm guessing Ford will provide little charity after losing $8 billion in a single quarter. A new rear end every 20K miles is rediculous. I've had the truck in 2 times for a leaking drain plug and it's still leaking.
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Joined: Jul 2005
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full synthetic oil is not black. even after 50k miles, it is still almost clear. i would drain that crap out, add full synthetic and the friction modifier and try that... as you said it happens only under acceleration between 50-60 MPH, that is classic gear mesh noise, not bearings.
