2003 Explorer Rear Differential Noise

[txsage]

Hello. I am a new member and this is my first post. I have a 2003 Explorer XLS 4.0L 6cyl with 73,000 miles. I hear this howling/whirring type sound from the rear at about 30mph that disappears at about 40mph and then it gets loud again at >50mph. The noise always disappears when I let off the accelerator.
My mechanic put it up on lifters and used a stethoscope to diagnose the noise. He says its a bad pinion bearing and I suggested to replace all the bearings if I wanted to have the job done. I'm now waiting on a written price estimate. My question: Does this sound right, that it would be a bearing and why does it only make noise at certain speeds?? He said if it were the gears it would be making more of a grinding noise.

 

[FourXFred]

TSB 5-12-6 is the ford notice on the rear axle whining. Ford will not cover the cost unless you are under the manufacturers warranty. I have heard the cost of this kit is about $1100 installed. Mine started whining around 50k miles, and I was able to nurse it along to 155k miles before it finally blew. I changed the rear diff oil every 15k (75w140 synthetic with the additive) and i think that helped a lot. I just had the rear end completely rebuilt by ford for $1700. So thats what your probably looking at. Good luck man.

 

[txsage]

Thanks for the input. I plan on discussing the quote with my mechanic. My hope is that I can get by with only replacing the bearings. I believe the TSB calls for replacing the bearings AND gears. I only drive about 5K miles/year and maybe the bearing only fix will last a while.

 

[txsage]

To FourXFred: You got me thinking.....did the oil replacement every 15K miles stop the whining?? With the amount of miles I drive Im wondering now if this might be worth a try. what do you think, or anyone else out there??? I want to make a decision fairly quickly.

Thanks in advance.

 

[jrford]

My trans guy when i had the trans rebuilt said something to the effect 'another thing you have to look forward to the the rear diff' leaks and whine. 'just a matter of time'
My guess is the seals are leaking water inside, maybe. the bearings rust up from the inside, some have said the R/P was still good. Someone had pictures on this site a while back.

I'd get a quote for complete rebuild then try and see how much just redo the bearings and seals. . .i'm only guessing at this point but i'm intrested in how it turns out.

Another thing, the Outer Wheel bearings and hubs could also make the noise, little cheaper to fix. . .

IMHO - I've been thinking when i do mine i just might do them all - Diff and the two rears.

 

[txsage]

Thanks for another good input. I will keep posting here until this thing gets fixed. I will include all the details in hopes it will help you and anyone else with a similar problem.
I just need to figure out which way is the best way to go given my situation and driving habits.

 

[FourXFred]

I changed the oil that often because it almost seemed to me like it was being burned. Not burned as in burning off, more as in the color and smell of it. It would cut down on the whining a bit, but basically i just lived with the noise and kept changing the oil every 15k religiously. And like i said, i got almost 160k miles out of it. I had to have it completely rebuilt only because the differential was actually locking and unlocking going around turns, especially at highway speeds. It would cause a loud thump and the truck would swerve on its own due to the diff unlocking. Frightening on the highway.

 

[txsage]

Thanks for the reply.....this helps. Guess if I decided to go this route one would never know when the end will come. It's worth considering, though.


I'm still trying to find out if my symptoms stated above really point to bearings, gears or both??
Anyone know or have ideas??

 

[Roger Edwards]

My 2002 explorer has started making a lot of noise like nobby tires but it's not the tires.
The tire place says that it's the rear end bearings. I tested each wheel seperately and both were noisy so it must be inside the differential. Sounds expensive. I wonder what the junk yards want for a used one from a newer model year if it will fit. My 1998 never had this problem and it had 155k miles on it when I sold it. What should I do?

 

[txsage]

Sounds like we are in the same boat. My mechanic told me to replace the rear end with a used one is less expensive but you never know if the used one is going to develop the same problem in a short period of time...then you are right back where you started. As far as expense goes...read post #2 under my original post. I'm still waiting on an estimate from my mechanic. I think for bearing replacement it's going to be in the neighborhood of $700.

 

[txsage]

Okay, here are the quotes. Rebuild with bearing replacement only:
Local mechanic I use: $950
Ford Dealership: $1000
Drive train shop: $700

Any comments....... from anyone???

 

[jrford]

sorry, been off site for a few days. . .
When i was getting the trans rebuilt i had asked my guy how much to regear from 3.55 to 3.73 and add a tructrac. .quote was about $1400. Mind you i have 4wd and that included the Fronts. $700 seems right. For me the $$$ is tight i'd check on junkyards and see how much for a used one. If i could get if for less than $200 i be tempted to go that way, but i would also save up for the $700. Also i'd expect about another 100-200 to install it unless you did it yourself. That puts you at about half the cost of a rebuilt and you still might have problems - i'd go rebuild this way.

But if you get it for about $100 and do it yourself . .no big loss - the junkyard would be the way to go.
Hopefully this helps.

 

[txsage]

sorry, been off site for a few days. . .
When i was getting the trans rebuilt i had asked my guy how much to regear from 3.55 to 3.73 and add a tructrac. .quote was about $1400. Mind you i have 4wd and that included the Fronts. $700 seems right. For me the $$$ is tight i'd check on junkyards and see how much for a used one. If i could get if for less than $200 i be tempted to go that way, but i would also save up for the $700. Also i'd expect about another 100-200 to install it unless you did it yourself. That puts you at about half the cost of a rebuilt and you still might have problems - i'd go rebuild this way.

But if you get it for about $100 and do it yourself . .no big loss - the junkyard would be the way to go.
Hopefully this helps.

Thanks for the input. I will not be doing this myself and I don't trust a used diff from a junkyard, so......here is what it looks like...around these parts a complete rebuild (all bearings and R/P gears) will run from $1k to about $1700. The specialty shop is at the low end, my mechanic is in the middle and the Ford dealer is at the high end. I can't find anyone that has used the specialty shop, so I have no track record.

Unless I am convinced otherwise I'm due to take the explorer to my mechanic Monday morning. My only concern with him is the 90 day warranty on labor. But, I guess 90 days should be long enough to make sure it's been done right.

 

[IZwack]

But if you get it for about $100 and do it yourself . .no big loss - the junkyard would be the way to go.
Hopefully this helps.

IMO, I wouldnt get a used rear differential unless its only a few thousand miles old or a few years old. The third generation Explorers' rear differential (the IRS) has a pretty short life compared to the second and first generation's differentials. So I think a used unit would probably only last a few thousand miles untill you have to go through the headache again.