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Ford Expedition Rear End/Differential Problems

36 messages,  Last post on Aug 05, 2009 at 3:53 PM

You are in the Ford Expedition Forum. Your Hosts are steve_ & tidester

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


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#17 of 36
Re: Differential Clutches Go Bad [roybus14] by benson10
Feb 09, 2007 (8:41 am)
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Replying to: roybus14 (Feb 09, 2007 6:58 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 36
Re: Ford Expedition rear differential leaking [sherekhan] by mikecole
Mar 02, 2007 (6:56 pm)
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Replying to: sherekhan (Jan 17, 2006 8:16 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 36
Re: Differential Clutches Go Bad [benson10] by aking2211
Mar 06, 2007 (11:44 pm)
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Replying to: benson10 (Jan 24, 2007 7:09 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 36
Call Ford's Customer Assistance Center by mikecole
Mar 07, 2007 (5:23 am)
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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.
#21 of 36
Try Ford Customer Care - Ford's Reputation is at Stake by benson10
Mar 07, 2007 (5:37 am)
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Too bad you didn't pick up on the rumbling sound/feel on your test drive, but I guess the condition of starting out in a turn may not have presented itself. Sounds like someone passed on a known problem to you. Ford is obviously VERY MUCH AWARE of the problem they have with these limited slip differential clutch packs. They have had to replace a ton of them. If you have any kind of relationship with your Ford dealer, start there. I bought my 2003 Expy new, and the rumbling came on gradually starting around 30K. I didn't know what it was, and one person even suggested that it was "characteristic" of four wheel drive vehicles. As the rumbling got worse, I finally went to my Ford dealer, who diagnosed the problem instantly. I called Ford Customer Care and worked through them. Ford covered $585 of the $835 charge to repair. Good thing because I was ready to write off the Ford nameplate forever (had already had a 4WD transfer case leak that cost me about $300).
#22 of 36
Re: Try Ford Customer Care - Ford's Reputation is at Stake [benson10] by mikecole
Mar 07, 2007 (5:47 am)
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Replying to: benson10 (Mar 07, 2007 5:37 am)

Why didn't they cover 100% under warranty? So far I've not had to pay anything other than the hassle of taking it up to them so much. My Exp is now out of warranty but the last repair came with a 12 month/12,000 mile warranty so that is what is covering my current repairs.
#23 of 36
No Help From Customer Care by tlbetts
Mar 14, 2007 (11:51 am)
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I own a 2003 Explorer with 55K Miles that experienced the vibration when turning right or left at a low speed. I called the dealer's service department and they immediately diagnosed the problem over the phone without driving the vehicle. The differential clutch pack replacement at the dealer cost $673.56 (originally quoted $850). I immediately called Ford Customer Care and after 3 days of "looking into the problem" they offered no financial assistance because the truck is not covered with an extended warranty. Ford KNOWS they have a serious issue and has issued two TSB on the problem. I think it is crazy they are not paying for their faulty part. I have sent a demand letter for payment and I intend on taking Ford to small claims court. I think everyone who is having this problem needs to call Ford to register a complaint and insist on financial assistance or a recall.
#24 of 36
Re: Try Ford Customer Care - Ford's Reputation is at Stake [benson10] by roybus14
Mar 15, 2007 (4:00 pm)
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Replying to: benson10 (Mar 07, 2007 5:37 am)

Yeah they are aware and it's in Technical Service Bulletins. I have an '04 Exp. XLT and about two months after I bought it brand new, it started doing it. I researched this problem and found a TSB on it, send it to the dealership in their appointment setup email and they fixed it free of charge.....
#25 of 36
Clutch Pack by sub9904
May 24, 2007 (5:35 pm)
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I own an Expy 05 bought in July of that year. Had the clutch pack worked on 3 times in about 8 months or less. So it's not just an 03-04 problem. Fortuantely, it looks like the 3rd time was the charm as I've had no issues in over a year. Other than that my Expy has been problem free. Knock on wood. Still it didn't keep me from buying an extended warranty just in case.
#26 of 36
Re: Rear End problem [melc] by syrupmakers1
Oct 21, 2007 (9:41 pm)
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Replying to: melc (Jul 07, 2006 10:47 am)

I have a 2003 Ford Explorer and I recently experienced the exact same problem related to the as I start from a dead stop and turning left and right. The problem was coming from the rear differential assembly area; specifically, the bearing assembly, cup, kit, gear and pinion had to be replaced. In addition, the additive oil and sealant around the rear differential cover needed to be replaced. In all, I had a $50 deductible under an extended warranty so the only costs that showed up on the invoice was $50, but I'm that the total cost was over $1000 (including labor)

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