2002 Ford Explorer 4x4 and noises

[home4sale2]

Hello everyone,

First post, new to this forum but not the concept. I have indeed spent the last hour reading posts and doing online searches, found nothing that resembles my question, the model year etc...

My 2002 explorer is currently in the shop due to the following problems:

1). I normally leave the truck in 4x4 auto but in winter last year tried to leave it in 4x4 high when the snow was heavy. On full turns (not straight and normal driving) such as reversing out of a parking spot, the 4x4 makes all kinds of clanking sounds as if things are snapping in and out of place, bending rods and such and then a tranny thump as if it's trying to catch up to all that is going on which lunges the truck forward. It is so scary for my wife that she refuses to put the thing in 4x4. It only does this when the wheels are turned most of the way to the left or the right. Normal reverse and forward procedure when pulling out of a parking spot. Dealer says this is normal, yeah right.

2). Lately I have been getting a sound when the truck is between 2500 to 3000 RPMs. Initially I thought it was the tranny but I get the same sound while the truck's in neutral so at least I can now duplicate it for the dealer to figure out what the problem is. Found another post with similar issue except his was during drive and not neutral.

I look forward to your thoughts and wisdom on this issue because I have a feeling I am not going to like what the dealer's gonna tell me. I fully plan to take another explorer for a test-drive out of their showroom. If that's how 4x4's are built on this model, there's an issue with explorers, period.

Thanks,

Sunny

 

[mrboyle]

When you were experiencing the problems in 4wd was it on clear pavement (no ice or snow)? If so this is normal. I assume you understand how a differential works? When you try to drive a 4wd with the t-case locked in while on a dry or solid (nothing that allows tire slip) surface the tires only want to go in a straight line. When you attempt to turn the traction is great enough that the differentials don't want to work. They try to apply equal power to all 4 wheels. This causes the drivetrain to bind up until something gives. This usually causes the vehicle to lurch, pop, etc... Basically, 4high should only be used when needed and you should ALWAYS unlock it when on any clear paved surface.

 

[home4sale2]

I have tried it on icy conditions, snow, rain as well as dry. Personally, the thought was to only leave it in 4x4 high if there is snow on the ground or ice. I agree that dry pavement offers no safety advantage, probably uses more gas than this beast already does and therefore will avoid. However, I am driving a rental from the dealer, an F150, and out of curiosity, I put it in 4x4 high on dry pavement and did not have the problems my explorer has.

Re: #2, the dealer said that apparently there was a new program for the drivetrain that eliminates the sound. I'll find out tomorrow when I pick it up. Perhaps it helps someone here.

Any other ideas?

Thanks again,

Sunny

 

[jayhawkexplorer]

You're doing a nice job of probably damaging that F-150. 4x4 HI is only for tough conditions like a foot of snow. You shouldn't need it almost ever on normal roads, even during the winter. I didn't need it once all winter in Wisconsin, so I know you don't need it in Chicago. I'm no expert on mechanical issues but it sounds like the problems with your Explorer are due to your prolonged use of 4HI. The sounds you get are normal from having the wheel cranked all the way to one side; my Ex does that, as does my roommate's GMC Sierra. Its odd that the F-150 doesn't do it, have you tried going in/out of a parking spot with it in 4HI. Regardless of the problems, at least you're still under warranty and you should know not to use 4HI unless the conditions are really bad. 4Auto handles almost anything the road throws at me, it should do the same for u.

 

[home4sale2]

Jayhawk, thanks again. I am not actively driving the F150 in 4HI, it was just a test that lasted 2 minutes in the parking lot to see if I get the same results. The concept that you guys are describing makes sense to me so thanks for the explanation.

Re: my Explorer, I bought it used so I am not sure if the previous owner had anything to do with it. I have always had the noise issue since the first time I put it in High mode, 10 months after my purchase, and yes, I tried it in various conditions but primarily during snow and sleet. I think I understand you perfectly that this is a useless feature unless you are in antartica or Michigan . I plan to leave it in Auto but in the meantime it's under warranty and like you said, might as well have it fixed while it is.

Not to extend the conversation but one clarification: I will hear this buckling sound, snap, bam, surge regardless of conditions (with 2 feet of snow on the ground in the Sierras for ex.) if the wheels are turned most of the way left or right, right?

Cheers,

Sunny

 

[TPLYNCH]

You shouldn't hear to much noise, feel lurching as long as the conditions are slippery enough to allow the binding wheel to spin freely. If you have very good tires that have good traction, it will be harder for the wheel to unbind, resulting in lurching/noises. As state above, try not to use 4Hi/4Lo on dry pavement, and avoid turning the wheels to full lock when in 4x4.

 

[F14CRAZY]

Hello everyone,

First post, new to this forum but not the concept. I have indeed spent the last hour reading posts and doing online searches, found nothing that resembles my question, the model year etc...

My 2002 explorer is currently in the shop due to the following problems:

1). I normally leave the truck in 4x4 auto but in winter last year tried to leave it in 4x4 high when the snow was heavy. On full turns (not straight and normal driving) such as reversing out of a parking spot, the 4x4 makes all kinds of clanking sounds as if things are snapping in and out of place, bending rods and such and then a tranny thump as if it's trying to catch up to all that is going on which lunges the truck forward. It is so scary for my wife that she refuses to put the thing in 4x4. It only does this when the wheels are turned most of the way to the left or the right. Normal reverse and forward procedure when pulling out of a parking spot. Dealer says this is normal, yeah right.

Sunny

First of all, what's wrong with Michigan winters...?

Anyway, normally, when turning and with 4x4 engaged, you will feel some lurching and some extra noise. Jayhawk explained all that pretty well. With my '93 Limited, it's noticed when the wheels are turned at about half way (or more) left or right. It is all normal, but you should try to avoid doing it if possible. When the snow gets really bad here, I do drive with 4x4 on the road but not over 35 MPH. When it's that bad though, it's unsafe to go much faster anyway. When in town and I have to make a 90 degree turn, I disengage it until I'm done turning and when doing other manuvers which take a lot of steering. (such as the parking lot situation you described)

Your dealer is not lying. What you are experiencing is normal. My uncle's new Trailblazer does the same thing. And he does use it during Michigan winters...

 

[recluse]

My 02 explorer also makes a funny rattling noise at about 2500 rpms or so. Keep me posted as to what your dealer says about that noise. I am currently trying to figure out how to fix it without spending a butt load of money.

 

[Flounder]

<< It only does this when the wheels are turned most of the way to the left or the right. >>

When you hear this noise, it's called binding. As one wheel tries to turn more than the other (in forward motion), the other cannot (think of an inside versus outside lane in running - one has a shorter distance per rotation). Every 4x4 I have driven does this when engaged in 4x4 high. My 1996 Explorer did it when it was in 4x4 Auto. Indeed, it is completely normal.

Not to rehash an above post, but 4x4 Auto should get you out of most snow situations in Chi-town and surrounding areas. High is meant for severe conditions or expecially if you're stuck (although Low may be better off for that). Good luck with the other problem!

 

[home4sale2]

Recluse,

I am waiting to get the truck back today but the 2500 RPM noise turned out to be a big job. What I was told is that the timing belt was not tensioned properly. Considering it's buried way inside, the entire top half of the engine had to be taken apart. To retension, they had to install cassettes. I didn't get into the details but I assume it's function is to take the slack out of the belt which was rattling and therefore causing that noise. My advisor (beginning to believe him more now, thanks to you guys) also said that the older explorers had this issue, 2003 and newer do not. It's a lot of work and in my case it was covered under warrantly.

I also had an occasional chirping sound during idle. That turned out to be a pully, the belt seemed to be ok.

Third problem seemed to be a noise coming from the front shocks every time I went over a speed hump (not fast). They replaced stablizer links and bushings.

The 4x4 system checked out fine as well, thanks for everyone's advice on what not to do.

Sunny

 

[home4sale2]

Recluse, looking at your profile, you have an '02 XLT like me. It should be covered under warranty as mine was. I was also told that Ford had a bulletin on this problem from 1996 to 2001 so others may qualify as well.

Here are some more details:

Replace primary chain tensionaer, jackshaft and crank-shaft sprockets
020801A Repl primary timing chain kit
264 W47
1 2U3Z*6D256*CA Kit-Tensioner Timing chain
8 VC*4*A ANTI/FZ
FC: N12 42
Part #: 2U3Z*6D256*CA

Hope this helps.