CarComplaints.com Notes: The 2002-2005 Explorer has a very well-established record of expensive transmission failure at under 100k miles. The Explorer has an enclosed transmission which is typically replaced with a rebuilt transmission at a cost of almost $3,000.
Adding insult to injury, the 2002-2005 Explorer also has a massive problem with the rear panel cracking. While it's a minor annoyance compared to transmission failure, ironically the crack usually goes right through the Ford logo.
There is definitely a problem with the axle seals on these things. I bought my explorer used with 40K and at that point it had both rear and front passenger seals leaking. Being a mechanic at the time I didn't mind pulled both front and rear diff to replace all seals. Within 20K the rear seals were leaking again which were replaced with Ford seals per the newest TBS. So rear diff pulled and seals replaced with aftermarket seals. Yet another 20K seals leaking again. I have found premium seals from Randy's ring and Pinion that are to solve the leaking problem. They are expensive for an axle seal but are supposed to not leak. I have seen good results with customers vehicles that I have installed these for diff rebuilds. I'll post once I get the time to pull the diff and put them in. I don't believe the problem is the differential it is the seals. The 8.8 differential has been around for a good while and has few problems except in the IRS explorers
Rear axle seals leaking on a 2005 explorer with 60,000 miles. It is just unbelievable that FORD can design and build a car in which the rear end leaks in a matter of 3 years. I have owned cars that were 20 years old with 200,000 miles that never had a rear end failure.
This is pathetic and the fact that it happens to a large amount of these vehicles and FORD does not accept responsibility for the design flaw makes this my last ford.
A D V E R T I S E M E N T S
There is definitely a problem with the axle seals on these things. I bought my explorer used with 40K and at that point it had both rear and front passenger seals leaking. Being a mechanic at the time I didn't mind pulled both front and rear diff to replace all seals. Within 20K the rear seals were leaking again which were replaced with Ford seals per the newest TBS. So rear diff pulled and seals replaced with aftermarket seals. Yet another 20K seals leaking again. I have found premium seals from Randy's ring and Pinion that are to solve the leaking problem. They are expensive for an axle seal but are supposed to not leak. I have seen good results with customers vehicles that I have installed these for diff rebuilds. I'll post once I get the time to pull the diff and put them in. I don't believe the problem is the differential it is the seals. The 8.8 differential has been around for a good while and has few problems except in the IRS explorers
- msw210, Osceola Mills, PA, US