2002 Ford Explorer XLT 4.0L Weird Noise 35-40mph | Ford Explorer Forums

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2002 Ford Explorer XLT 4.0L Weird Noise 35-40mph

bweigum

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I have a problem with my Explorer and it only seems to occur in the 35-40mph range. I keep trying to duplicate the noise with not much luck. I guess you could say it sounds like a grinding noise but I like to describe it as someone trying to release flem from their throat. Last time I heard it I was going 38mph and the RPM's were barely over 1k and I was maintaining that speed with foot barely on the gas peddle. As soon as I release my foot from the gas the sound goes away. If I'm accelerating at a normal acceleration I never hear this. It only happens when I'm cruising and happen to be at the 35-40mph speed with my foot barely on the gas. Anyone have any idea what could be wrong? No sensors have come on since I've noticed the sound.
 






It's your rear end differential....it's a whirring/whine sound, and if you do some browing on the first few pages here you will see discussions about it.

I have the identical problem as well. Don't let someone tell you it's a bearing....bearings don't stop making noise when you let off the gas.

Mine is pretty much in the same range as yours, starts at 35MPH until about 42MPH....

It's a VERY COMMON PROBLEM on 3rd gen's. What can you do? Well you can replace the rear diff clutch pack and ring/pinion (which was done to mine by Ford but 40k miles later the noise is back...), you may also have some luck replacing the diff fluid with a 75w-140 synthetic with some additional friction modifier (I did this and it didn't really help mine at all). But pretty much the consensus here is to just put up with the noise unless you want to replace the diff clutch pack and ring/pinion set.
 






If the rear end is left alone what is the worst that can happen. Will it just stay noisy or will there eventually be a breakage?
 






Curious?

Has anyone on here tried to re-set the pinion depth? If going in a straight line then I don't see how the clutch pack would have anything to do with the whine/howl sound. If a new gear set is improperly set-up then it can howl also. I am wondering what would happen if a fellow had the shims, a new crush sleeve, and a little marking compound. Just wondering if anyone has tried? Maybe the same results as replacement. May go away for awhile.

Now I am not recommending it, but I would not be afraid to try it on my own vehicle in the face of buying an entire gear set since the shims and bearings in an install kit can be re-used if done right.

DMC
 






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