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Ford Expedition Rear End/Differential Problems

41 messages,  Last post on Sep 10, 2011 at 12:46 AM

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What is this discussion about? Ford Expedition, Car Warranties, SUV

Messages Page 2 of 4

#11 of 41 ford expedition by suave2

Sep 19, 2006 (2:49 pm)

i financed a 1998 expedition with 39047 miles 3 years ago(aug 2003) from a dealership.it came with 22inch rims.i changed the brakes and rotors and found out there was no sway bar!! 6 months after purchase i had problems with the rear axle.i had a hole in the differential cover and was leaking fluids.i bought a heavy duty cover and had it assembled and refilled with the proper fluid.about 5 moths after my differential gears broke,warranty was run out and i paid $2200 for a new axle and labor.COOL!!!!aug 2005 my lower rod bearings were no good{engine problems),i took care of problem and tried to sell the truck...i got a great deal on an extended warranty and decided to keep it and now the heater core doesn't work and it's not covered on warranty.yesterday while driving he just shut off while coming to a light.{luckily i have a jump box in back}it has been well maintained and i now only have 77000 miles {mostly highway}

#12 of 41 Re: Expedition Rear-End Problem caused serious accident [lequia] by tackster87

Oct 31, 2006 (6:36 am)

Replying to: lequia (Mar 02, 2006 8:09 pm)
We have a 2003 Expedition and it has had the rear end cluthes replaced four times in the last two years. We recently had in the shop again and they decided to replace all the hard parts in the rear end and the cluthes. It was only a week ago it was in the shop and the vehicle is doing it again. Our expedition only has 55,000 miles on it and we are on our third set of tires. I think the rear end problems have worn our tires out too.

#13 of 41 Re: Rear End problem [melc] by ovrwrkd72

Jan 03, 2007 (8:24 pm)

Replying to: melc (Jul 07, 2006 11:47 am)
I purchased an 04 EB series about a week ago and heard the same rubbing, vibration sound when turning left/right from a stop. I just took it in this morning and got it back this evening, (fixed form the dealer) and here is what I was told. The limited slip rear differential requires an additive mixed with the gear lubricant. This ensures that the oil (grease) can work its way into the clutch and stop the grabbing when one tire is turning more than the other (turning from a stop) Anyway, I haven't heard or felt anything since I got it back so... These are reputable mechanics and dealers however and this is the 3rd vehicle i have purchased from them & they have always done me right.

#14 of 41 Re: Rear End problem [ovrwrkd72] by alwaysfords2

Jan 04, 2007 (8:19 am)

Replying to: ovrwrkd72 (Jan 03, 2007 8:24 pm)
Even with the additive the clutch packs go bad. Changing the fluid will buy you a little time, but you'll be back. I'm on my third set, and going for fourth when I get a chance. I haven't had to pay for any of them yet, but I'm going to be even more annoyed when I do. They used to replace the whole axle assembly but stopped that when they realized what it was costing. Instead they now send the dealer 15 individual part numbers and have them do the leg work of assembling it. I have 70k miles on it ('03)

#15 of 41 Differential Clutches Go Bad by benson10

Jan 24, 2007 (8:09 pm)

At last, after thinking that all the shuddering when starting a left or right turn from a dead stop was "characteristic of 4 wheel drive ... the awful truth. This is a well known problem associated with improperly seizing limited-slip differential clutches. Ahhhhhh the good news, Ford will repair their design/build fault in my 2003 Expedition for only $835 of my money. I started noticing this uncomfortable rumbling and shuddering over a year ago, and someone mentioned that 4 wheel drive vehicles did that. So for more than a year, I've suffered in silence while the racket became more and more annoying. This problem on top of a transmission/transfer case leak at 50K ($357.46 with ZERO assistance from Ford) has pretty much convinced me that I am going the Toyota-Honda route in the future. It's bad enough that Ford is building (in my case) an inferior product, but you'd think that they would be a little more accountable.

#16 of 41 Re: Differential Clutches Go Bad [benson10] by roybus14

Feb 09, 2007 (7:58 am)

Replying to: benson10 (Jan 24, 2007 8:09 pm)
I purchased my 04 XLT brand new in Feb. 2004. About a month or two after I had the vehicle, I started experiencing the same problem with rear differential. I researched this by going to NHTSA's website and looking for TSB's on this. I found it, printed it out took it to the dealer and they fixed everything free of charge. This is a known problem with 03 and 04 Expeditions and if your truck is under warranty, they should not have charged you for it.

#17 of 41 Re: Differential Clutches Go Bad [roybus14] by benson10

Feb 09, 2007 (9:41 am)

Replying to: roybus14 (Feb 09, 2007 7:58 am)
My story had a pretty good ending. At 72K, Ford replaced the limited slip differential clutch packs for $250. Much better than the $835 originally quoted. Restored a good bit of my faith in Ford.

#18 of 41 Re: Ford Expedition rear differential leaking [sherekhan] by mikecole

Mar 02, 2007 (7:56 pm)

Replying to: sherekhan (Jan 17, 2006 9:16 pm)
I have a 2003 XLT Expedition that I bought used with only 900 miles on it. It now has 40,000 miles on it and has had 4 clutch packs and 2 ring gears put in it. I noticed tonight that it is doing it again and worse than before. I haven't had to pay for the parts and nor do I plan to since this has been an on going issue. I only got about 4000 miles since the last repair. I will be calling Monday to schedule the repair.

#19 of 41 Re: Differential Clutches Go Bad [benson10] by aking2211

Mar 07, 2007 (12:44 am)

Replying to: benson10 (Jan 24, 2007 8:09 pm)
I just bought a used 2003 Ford Expedition and noticed the grinding and rumbling right away when I turn. Took it to the Ford dealership and said it would cost $988+tax to repair, does anyone know how i can get assistance from ford to repair. No way I can afford to repair.

#20 of 41 Call Ford's Customer Assistance Center by mikecole

Mar 07, 2007 (6:23 am)

Here is the the number 800-392-3673. I'm currently dealing with them regarding my Expedition. So far they have been helpful and are looking closer at my vehicle. The dealership currently has my Exp. so they can put the 5th set of clutch packs in (not including the original set). I would call them and tell them that you have researched online and see that this is a on going problem with this vehicle. I think you could get them to help, but you never know.

Messages Page 2 of 4

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