6th-Gen Explorer Differential Setup & Why Bracing Matters

[SClark08]

The 2020+ Ford Explorer features an independent rear suspension (IRS) with a rear-mounted differential, secured to the subframe via three mounting points (typically two at the front and one at the rear-driver side). Factory rubber bushings help dampen vibrations but allow excessive differential movement under load—especially during hard acceleration, towing, or aggressive driving. Check out Fleet Management’s video for a visual:

Why Differential Braces Matter​

1. Reduces Differential Movement – Stock mounts allow axle wrap and wheel hop, leading to instability and premature drivetrain wear.
2. Improves Power Transfer – A brace keeps the differential rigid, minimizing energy loss and maximizing traction.
3. Prevents Differential Failure – Excess movement stresses mounting points, causing case cracks or bolt failure, particularly in high-torque models like the Explorer ST.
4. Enhances Towing Stability – A reinforced differential distributes load better, reducing flex and improving durability.

​

How Differential Braces Work​

• Reinforce the Housing – Braces add extra support to the differential case, reducing flex under acceleration.
• Bolt-On Installation – Most attach to factory mounts and incorporate polyurethane or solid bushings to limit movement while maintaining some vibration damping.

If your Explorer is strictly a family hauler or mall crawler, the stock setup is fine. But if you plan on towing, passing/overtaking, police pursuit, or tackling sand dunes and service roads, a failed differential can leave you limping home—waiting for a dealer to source a rear bolt - or worse, hog out your differential - is no fun.

---

Differential Brace Options​

1. FENFABrication "Diffy Stiffy" Brace– $168.00
   • Simple L-bracket with a dampener between the flange and subframe.
   • FENFABrication 2020+ Ford Explorer "Diffy Stiffy" Brace - FenFabrication
2. AWR Racing Rear Differential Mount(AWR-E3301) – $294.99
   • Upgraded L-bracket, laser-cut, CNC-folded, powder-coated with a dampener sleeve.
   • 2020 - 2025 AWR Racing Ford Explorer Rear Differential Mount
3. cp-e xFlex Differential Mount(FDXM00021B) – $499.99
   • Four-bolt diff cover bracket + subframe-mounted dampener hub, 6061 T6 aluminum, anodized black.
   • xFlex™ Differential Mount for 2020+ Ford Explorer ST EcoBoost – Custom Performance Engineering
4. ID Speed Shop Rear Differential Brace(IDSS-EXP-RDB) – $499.99
   • 6061 T6 billet aluminum, anodized black, nearly identical to cp-e’s xFlex.
   • ID Speed Shop - 2020+ Ford Explorer Rear Differential Brace
5. Livernois Motorsports Differential Brace(LPP931011) – $499.99
   • Similar to ID Speed Shop and cp-e, but anodized blue.
   • | LPP931011 | Livernois Motorsports
6. Steeda Explorer Rear Differential Brace(555-8141) – $524.95 - $554.90
   • CNC-machined 6061 T6 billet aluminum, dual bushing support, non-anodized.
   • Steeda 555-8141 Explorer Rear Differential Brace (20-25)

Most of these are marketed for the Explorer ST, but they also fit the King Ranch and Hybrid (Police Interceptor only) models. The XLT and Limited trims have a smaller differential, making them incompatible. But what about the Timberline?

The Timberline Dilemma​

Marketed as the off-road sibling (2021-2024), you'd assume the Timberline is exempt from differential mount issues... Nope. Absent compatibility info, I decided to find out.

After researching designs, installation methods, and pricing, I liked AWR’s brace best. I reached out to AWR to confirm fitment, and while they didn't have any data on the Timberline, they provided a mounting diagram for me to compare. I took caliper measurements of my '23 Timberline’s differential, noting near-perfect bolt spacing. The only uncertainty was geometry relative to the subframe. My makeshift solution? Masking the differential, rubbing graphite over it, transferring it to graph paper, and measuring from there (not perfect, but creative - Indiana Jones would be so proud).

AWR’s response? They sent me a prototype to test-fit. Four days later, I had a package containing the brace, hardware, and some AWR swag.

Installation & Final Thoughts​

AWR provides an installation video on their product page, and YouTube channels like Fleet Management and Knight’s Garage offer additional insight. I've uploaded my installation experience on my channel: AWR Rear Differential Brace for 6th Gen Explorers - Timberline Edition?

AWR impressed me with their responsiveness and engagement from the start. A simple inquiry turned into a direct conversation with their team, leading to technical discussions and, ultimately, a prototype shipped to me—with no money exchanged. Their commitment to expanding product compatibility and supporting the Explorer community speaks volumes about their customer-first approach.

My intention is to repay their kindness by championing their product and spreading awareness; the fit and quality is something you can feel. As of this posting, I’ve only logged a mile with the brace installed, but I didn’t need to adjust the pitch of my differential for mounting, nor do I feel it altered its resting position. The OEM design was likely intended to strike a balance between reliability and ride quality; I will continue monitoring my Timberline’s handling and watching for any premature wear. However, from installation to test drive, AWR’s brace already feels like a solid investment. Now we know:


Application:

• Ford Explorer ST 2020-2025
• 6th generation Ford Explorer Police Interceptors
• Ford Explorer King Ranch
• Ford Explorer Timberline

Disclaimer: As of this posting, only one (1) mile has been driven with the differential brace installed, and a long-term review is pending. AWR assumes no liability for any issues resulting from aftermarket modifications to Ford Explorer Timberlines. Modify your vehicle at your own risk.

 

[2020FordRaptor]

Great write up. I’d like to add that the rear differential failures for all but one, have been all on 1-bolt rear subframe Explorer STs which have snapped their bolts. Also, the best rear differential is the ID-Speed unit. I’m not a fan of the AWR unit because it contributes to a weird torsional effect.

 

[SClark08]

Great write up. I’d like to add that the rear differential failures for all but one, have been all on 1-bolt rear subframe Explorer STs which have snapped their bolts. Also, the best rear differential is the ID-Speed unit. I’m not a fan of the AWR unit because it contributes to a weird torsional effect.

Can you elaborate on that? Is it because the AWR hinges vertically, whereas the IDS allows for freedom of movement (however, damped)?

Edit: One of the key factors that led me to choose AWR was accessibility. I wanted to ensure that servicing the differential would be straightforward for any dealership, without requiring extra labor to remove a brace—let alone the risk of reinstallation being forgotten (or omitted because it isn’t OEM).

 

[2020FordRaptor]

Can you elaborate on that? Is it because the AWR hinges vertically, whereas the IDS allows for freedom of movement (however, damped)?

The ID-Speed unit is meant to mimick the 2-bolt subframe. The AWR helps, but because of the unsymmetrical design. It causes the rear differential to twist, putting more stress on one side. Here’s a video that shows it:

 

[SClark08]

The ID-Speed unit is meant to mimick the 2-bolt subframe. The AWR helps, but because of the unsymmetrical design. It causes the rear differential to twist, putting more stress on one side. Here’s a video that shows it:

That was awesome. I may try an insert (in conjunction with the AWR). Now I’m curious about their drive train support bracket.

 

[2020FordRaptor]

That was awesome. I may try an insert (in conjunction with the AWR). Now I’m curious about their drive train support bracket.

Unless you’re launching the car a lot, it’s not needed.

 

[SClark08]

Unless you’re launching the car a lot, it’s not needed.

Not with the 2.3L. I’m only interested in making it more robust. The drive train brace’s installation looks more involved. The JXB bushing plug on the other hand; I can get behind that.

 

[Rick]

The 2020+ Ford Explorer features an independent rear suspension (IRS) with a rear-mounted differential, secured to the subframe via three mounting points (typically two at the front and one at the rear-driver side). Factory rubber bushings help dampen vibrations but allow excessive differential movement under load—especially during hard acceleration, towing, or aggressive driving. Check out Fleet Management’s video for a visual:

Why Differential Braces Matter​

1. Reduces Differential Movement – Stock mounts allow axle wrap and wheel hop, leading to instability and premature drivetrain wear.
2. Improves Power Transfer – A brace keeps the differential rigid, minimizing energy loss and maximizing traction.
3. Prevents Differential Failure – Excess movement stresses mounting points, causing case cracks or bolt failure, particularly in high-torque models like the Explorer ST.
4. Enhances Towing Stability – A reinforced differential distributes load better, reducing flex and improving durability.

​

How Differential Braces Work​

• Reinforce the Housing – Braces add extra support to the differential case, reducing flex under acceleration.
• Bolt-On Installation – Most attach to factory mounts and incorporate polyurethane or solid bushings to limit movement while maintaining some vibration damping.

If your Explorer is strictly a family hauler or mall crawler, the stock setup is fine. But if you plan on towing, passing/overtaking, police pursuit, or tackling sand dunes and service roads, a failed differential can leave you limping home—waiting for a dealer to source a rear bolt - or worse, hog out your differential - is no fun.

---

Differential Brace Options​

1. FENFABrication "Diffy Stiffy" Brace– $168.00
   • Simple L-bracket with a dampener between the flange and subframe.
   • FENFABrication 2020+ Ford Explorer "Diffy Stiffy" Brace - FenFabrication
2. AWR Racing Rear Differential Mount(AWR-E3301) – $294.99
   • Upgraded L-bracket, laser-cut, CNC-folded, powder-coated with a dampener sleeve.
   • 2020 - 2025 AWR Racing Ford Explorer Rear Differential Mount
3. cp-e xFlex Differential Mount(FDXM00021B) – $499.99
   • Four-bolt diff cover bracket + subframe-mounted dampener hub, 6061 T6 aluminum, anodized black.
   • xFlex™ Differential Mount for 2020+ Ford Explorer ST EcoBoost – Custom Performance Engineering
4. ID Speed Shop Rear Differential Brace(IDSS-EXP-RDB) – $499.99
   • 6061 T6 billet aluminum, anodized black, nearly identical to cp-e’s xFlex.
   • ID Speed Shop - 2020+ Ford Explorer Rear Differential Brace
5. Livernois Motorsports Differential Brace(LPP931011) – $499.99
   • Similar to ID Speed Shop and cp-e, but anodized blue.
   • | LPP931011 | Livernois Motorsports
6. Steeda Explorer Rear Differential Brace(555-8141) – $524.95 - $554.90
   • CNC-machined 6061 T6 billet aluminum, dual bushing support, non-anodized.
   • Steeda 555-8141 Explorer Rear Differential Brace (20-25)

Most of these are marketed for the Explorer ST, but they also fit the King Ranch and Hybrid (Police Interceptor only) models. The XLT and Limited trims have a smaller differential, making them incompatible. But what about the Timberline?

The Timberline Dilemma​

Marketed as the off-road sibling (2021-2024), you'd assume the Timberline is exempt from differential mount issues... Nope. Absent compatibility info, I decided to find out.

After researching designs, installation methods, and pricing, I settled on AWR’s brace. I reached out to AWR to confirm fitment, and while they didn't have any data on the Timberline, they provided a mounting diagram for me to compare. I took caliper measurements of my '23 Timberline’s differential, noting near-perfect bolt spacing. The only uncertainty was geometry relative to the subframe. My makeshift solution? Masking the differential, rubbing graphite over it, transferring it to graph paper, and measuring from there (not perfect, but creative - Indian Jones would be so proud).

AWR’s response? They sent me a prototype to test-fit. Four days later, I had a package containing the brace, hardware, and some AWR swag.

Installation & Final Thoughts​

AWR provides an installation video on their product page, and YouTube channels like Fleet Management and Knight’s Garage offer additional insight. I've uploaded my installation experience on my channel: AWR Rear Differential Brace for 6th Gen Explorers - Timberline Edition?

AWR impressed me with their responsiveness and engagement from the start. A simple inquiry turned into a direct conversation with their team, leading to technical discussions and, ultimately, a prototype shipped to me—with no money exchanged. Their commitment to expanding product compatibility and supporting the Explorer community speaks volumes about their customer-first approach.

My intention is to repay their kindness by championing their product and spreading awareness; the fit and quality is something you can feel. As of this posting, I’ve only logged a mile with the brace installed, but I didn’t need to adjust the pitch of my differential for mounting, nor do I feel it altered its resting position. The OEM design was likely intended to strike a balance between reliability and ride quality; I will continue monitoring my Timberline’s handling and watching for any premature wear. However, from installation to test drive, AWR’s brace already feels like a solid investment. Now we know:


Application:

• Ford Explorer ST 2020-2025
• 6th generation Ford Explorer Police Interceptors
• Ford Explorer King Ranch
• Ford Explorer Timberline

Disclaimer: As of this posting, only one (1) mile has been driven with the differential brace installed, and a long-term review is pending. AWR assumes no liability for any issues resulting from aftermarket modifications to Ford Explorer Timberlines. Modify your vehicle at your own risk.

Nice writeup. I set you up with a 3 month Elite membership.

 

[SClark08]

UPDATE: I’m incredibly impressed with AWR Racing — they reached out a few weeks back and offered to replace the prototype (green) brace I had with a final production unit in a beautiful gloss black finish. Their generosity, professionalism, and commitment to customer satisfaction truly stand out. It’s rare to find a company this responsive and passionate about their work. I genuinely can’t recommend them highly enough.

 

[Rick]

That was a nice gesture on their part.

 

[chazglenn3]

Has this issue been resolved on the 2025 Explorers with the 3.0L?

 

[peterk9]

Has this issue been resolved on the 2025 Explorers with the 3.0L?

As far as I recall, there were no changes made to the setup except the 'strengthening' of the parts used. I believe that was posted some time ago.

Peter

 

[chazglenn3]

Thanks!

 

[2020FordRaptor]

Has this issue been resolved on the 2025 Explorers with the 3.0L?

No, all they did was somewhat detune the car when launching it. Still highly recommend a diff brace:

Let’s talk Differential Braces and Why They are Needed!

Hello everyone! Today we will be talking about differential braces, as well as why they are needed for most 3.0L Explorers. Enjoy! 1-bolt Subframe In early-2021 Ford decided to cut costs and put t…

explorerst.wordpress.com

 

[BradleyFord]

This was a great write up! I'm curious though, should I need to put this on my 2025 ST-Line 2.3L? Is installing this something that would break the warranty?

 

[2020FordRaptor]

This was a great write up! I'm curious though, should I need to put this on my 2025 ST-Line 2.3L? Is installing this something that would break the warranty?

Can’t install it on the 2.3L. Different rear differential.

 

[Dale5403]

Can’t install it on the 2.3L. Different rear differential.

Ford parts shows part # S-604-D fits for Explorers with 2.3 and 3.0 engines.

But to the OP you may not need a brace for your ST Line. I have not heard of an issue with the bolt breaking on the 2.3 engine.

 

[Baysider]

My wife’s 2020 Explorer XLT 2wd 2.3 Ecoboost with 95k miles on it was delivered without the one bolt recall not having been done. I noticed this and mentioned it to our sales rep who said all recalls are completed on certified used cars before they are delivered. Two days later the dealer’s shop manager called all humble and asked us to bring it in to have the one bolt recall done. They gave us a loaner Bronco. Three days later and we haven’t been called to pick it up. Any idea what the hold up is? Now the 4th of July weekend.

 

[Baysider]

Edit: Pardon my grammar.

 

[Dale5403]

I wonder if they did not have the parts in stock. I would call them when they reopen and ask. In the mean time, enjoy their Bronco.