Vehicle, Problem, Qualifications:
2017 Explorer Platinum. <2000 miles. Flutter/vibrations/wobble/shudder/et al... 40-70mph range. Personal background: Aero engineering degree; military flight test experience, decades of military fighter time. Backyard mechanic with descent wrenching skills. Shared only to let you know I'm pretty sensitive about machines and out of the ordinary vibrations/ noises. When you only have one engine and you're about to cross an ocean, you get pretty particular about your machine operating properly.
Summation IMO:
Problem is aerodynamic. Ford likely knows about it, but will never admit it. In their words (offered from previous posts) this is "a normal characteristic of the vehicle". No real options available other than to put up with it. Long shots of TSB with fix, using lemon law to return to dealer, or class action law suit, but I don't see any of those things actually happening. Pretty pathetic for a $55K sticker vehicle, but that's the world we live in.
Some details, experiments, findings and rants:
Test driving the vehicle before purchase I knew nothing about the lane departure system. On a rough cow path of a road, the system was constantly using the "wheel shaker" to warn me that I was close to the edge of the (single) lane. I thought something was severely wrong with the suspension, so I stopped and shut off any automated technology pieces that I could find and the problem went away. I actually thought this was funny at the time. Fast forward about a week. After discovering the front 1/3 of the vehicle had overspray on it (unknown why and still trying to get that resolved), we noticed the flutter problem while driving down a newly paved asphalt road. Normally on a road like this, I was expecting absolute smooth silence; that was not the case. What could this be? How could I be so stupid to buy another Ford product after my 2013 Edge turbo started to fail at 40K miles and Ford wouldn't do anything about it. Well, I come from a long line of Ford mechanics and owners, so I thought I'd give them one last chance even after I said "that's it" after the Edge experience. BTW, the only reason we would up with the Explorer instead of a new Edge is they redesigned the seats, made the seating edge bolsters bigger, and moved part of the seat frame up in to the bolster; didn't like sitting on steel railing since I've already logged >3000 hours of that in ejection seats, so we bought the EX Platinum. I digress, but the whole seat issue, spec brochures, what is actually available in the various vehicle models, etc was pretty sad too. I wouldn't want to try to order a new vehicle from the factory these days because I'd bet you'd wind up with something unexpected when the vehicle actually showed up on the lot. As I said, I digress.
From now on, let's refer to the flutter/shudder/etc problem as "Ford".
Found the TSB for the windshield/wiper cowling. Taped up the cowling and went one step further by plugging the gap between the cowling and hood with material as well as plugging the flow through vents from the front bumper to front wheel wells. No change in Ford.
Spent time analyzing sounds and frequencies from the tires because I had low expectations about Hankook's. Determined mostly that the freq band was too high for the Ford problem and the tires were only producing what I'd consider standard road noise.
Found that the frequency of Ford is the same that you get when putting both rear windows half down which BTW almost literally shakes the car to pieces at standard highway speeds. The front passenger seat was shaking so badly that it was almost funny, if not for the fact I just spent more on this vehicle than I made the first 2 years of being in the service.
Took all the plugging material out/off as well as the tape, then took the vehicle to about 55 mph which seems to be the worst speed for Ford. Interesting that used to be the speed limit for the country, but that has nothing to do with this. So as the Ford problem was shaking away at 55 mph, I used the remote mirror folding button to crank the rear view mirrors in. Ford didn't go away, but it did seem to reduce in amplitude furthering my belief that Ford is an aerodynamic issue. So let's address that.
If any of you are older than 50 or in to antique cars, you'd be hard pressed to find any kind of aerodynamic instability that this Explorer has when you lower the back windows. Why? Material thickness. Compare the thickness of the exterior door panels, hood, roof, (all the skin on a vehicle) of a 1955 Mercury Monterey with anything made today. No comparison. The designers still add all the wonderful muscle car year curves to modern vehicles but apparently don't take in to consideration the aerodynamic stability of the structure across the normal operating envelope. Back in the day, you could actually have a fender bender without totaling the vehicle; now I swear the hood and doors get huge dents in them just from looking at them. I must admit I have no clue if they test these vehicles in any wind tunnels test or the like during the design phase, but I'd bet whatever is done isn't worth much. Perfect example of lack of adequate testing before fielding is the Ford My Touch system (what a piece of crap and I'm starting to think the Sync3 is just a faster operating piece of crap, but again, I digress). If you are the Ford company, what do you do if you discover the Ford flutter problem during test driving? Probably too late and expensive to retool. Too thin of metal would require some internal stiffening or external fencing to redirect the airflow and limit the Ford experience. Oops, external fixes, there goes the gas mileage. So you race in to production and hope less than 1% of the 400000 units sold are to people who will notice or care and that of those 1% that maybe only 1% of those will try to do anything about it which is how we get to this great forum. Wish I had done better research before buying this EX.
Does anyone else find it odd that Ford thinks ""a normal characteristic of the vehicle" is synonymous with safe/comfortable and "not a problem" somewhat strange? Another sign of the times. Gotta think Henry Ford is rolling over in his grave with stuff like this. In the aircraft test world "a normal characteristic of the vehicle" might get you real dead until the correct redesign was implemented. I'm certainly not saying this is necessarily a safety issue, but it is certainly IMO a disaster somewhere down the road for the company. You can't continue to field pieces of expensive crap (best example was FMT) and not suffer repercussions. The younger generation doesn't have any loyalty like previous generations did/do, so Ford needs to get this addressed ASAP. Our son already bailed on Ford and is driving something else. Same with our daughter. This will DEFINITELY be my last new Ford. I'm still running my '03 F250 and my '63 Falcon (BTW, my other Falcon did Mach 2).
Somebody please prove me wrong with my theory that this is an aerodynamic issue without a current quick fix. On a positive note, this vehicle still beats driving a horse and buggy through snowy Ohio back county.
Thanks for reading and to all the posters before me on this frustrating and depressing issue.