Gear Shift Broke Off in Hands!!!

[newtek007]

Well. Here goes. Thought somebody might be able to use this info about my experience with my wife's 2002 E.B. Explorer.
I got the call from her this morning that she just arrived at work and the gear shifter broke off in her hands. Could not get the key out so I had to haul over and trade out trucks.
Once I got it home I found that a major aluminum part had sheared off! Now, I am no expert when it comes to metal, but I do tinker with aluminum and soft metals in my garage making stuff for RC Airplanes. So, I know a little about this kind of stuff and I know that what I am looking at should have never broken, unless the batch of aluminum they used to cast the part was tainted with something or maybe an air bubble got in the cast.
But, here are the pictures that I have taken.
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9354.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9355.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9360.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9358.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9356.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9366.jpg

http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9367.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9368.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9369.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9370.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9371.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9371-1.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9373.jpg
http://img.photobucket.com/albums/v679/newtek007/2002%20ExplorerShifter/IMG_9374.jpg

I have not taken pictures since I have Reattached the pieces using PB Weld. I have had great results using this stuff in the past. It is curing in the garage as I write. Hopefully, the jury rig piece will hold up to the stress of shifting the column.


Gear Shift Broke Off in Hand

 

[34Ford]

Oh my gosh. How I hate to see these pics.

I spent 4 hours last night trying to take the speedometer assembly out to try and see if I could find why the diagnostic leds are dim.

And in the process I broke the plastic adjustment for the shift indicator!!!!! What a nightmare.
I had tore out most everything before I saw you can slip the loop in the cable over the head of the screw.

I hope your PB weld holds, but being a 30 year machinist I dont think I would trust it in such a high stress spot.

So how long ya been playing with RC?

 

[newtek007]

I'm with you on the PB Weld, but it is a last ditch effort before I make the dreaded trip to the junk yard. I guess I'm still in shock that this piece actually broke. I have it back together and it is taking hammer blows ans so forth. I guess I'll just put it back in and cross my fingers until next time. I found the clockspring to be bad too, so I'm installing a new one.

I've been into RC airplanes for about 10 years or so. I enjoy building them from scratch more-so than flying. Always loved aviation. My poor man's attempt to flight I guess.

 

[34Ford]

I started into RC way back in '74

Had everything, upto last year and now Im trying helicopters.
Currently building a Vario Benzine gasser.

 

[newtek007]

I'm getting ready to dive into helis myself. Here's my club's web site:
http://www.newportnewsrc.org/
I'm going to start with the TRex and see how that goes. I have some experience with 'em and have flown my friends a couple of times. Just alot of money!

Well, I tried putting stress on the part and it broke, as I thought it would. I guess I have to go to the junk yard and try to get an entire steering column. My day has just been made.

 

[34Ford]

A T-Rex is a very affordable heli and abundant parts.
But I have learned that the bigger the heli the easier to learn on.

You wouldn't be interested in selling me a gear shift indicator assembly would you?

I made a new adjustment tube today out of nylon to get me back up and running, but dont know if it will work till tonight.

Here is some of my toys.
http://www.runryder.com/helicopter/gallery/35194/

 

[newtek007]

Ummm.. ok. That's a big heli! Chrome Plated motor huh? My budget doesn't go that high, but it's good to see that I'm not the only person who loves tinkering with EVERYTHING!!!

You finished the Heli yet?

Sidenote: Gotta but a new steering colum because the metal piece is made out of POTMETAL. Ford ain't quality anymore.:thumbdwn:

 

[newtek007]

Is there a TSB On The Gear Shifter???

Is there any type of TSB on this Gear Shifter problem? I just ordered a new upper steering column and I am hoping that the part that broke is revised. Anyone have any clues to this?

I don't see too many people on this forum having this problem?

 

[the-commuter]

Same thing happened to me while driving my wife's 02 XLT Explorer. I called the dealer and they said 'common problem' then proceded to tell me that the only fix was to purchase the ENTIRE STEERING COLUM for $690! I told him that he must be very proud of that part and that he could keep it. Called a few wrecking yards, they want $350 for a used steering colum... Problem with the used one is that the shift tube may already be breaking. So, being a mechanical engineer, I redesigned the part and am having a couple machined out of aluminum. I have replaced all the press fit nuts and pins with screws so you can assemble it with standard tools. If it works out, I would be willing to sell the extra one for what it cost me to build, $220. Send me an email if you are interested bruced@lathropengineering.com

Just FYI, the original part is made from cast Zinc (poor design, poor material choice)

 

[newtek007]

Thanks

Thanks for the offer, but I went ahead and "invested" in a new steering column. The part hasn't been been revised. They just upgraded the entire Explorer to the center shift style and abandoned the shift column style.
I'm pretty sure that with all the problems I have had with this truck, I'll be getting rid of it before the shifter breaks again.

 

[bobbydaniel]

IS there no other option other than to replace the whole column ? Please help !!!!!!

 

[newtek007]

not that I know of

Not that I know of. Did yours break? If you look at the design of the unit you will see that it is made of pot metal. If you know someone at a machine shop, they MIGHT be able to design another one. However, the part was cast in pot metal as one unit. The design is very poor. They did not redesign it because it would not be cost effective due to the next year model coming out.

I tried JB Welding it together. The amount of pressure on that spot is tremendous. All of the pressure of the shifter is at this one point. Pot metal doesn't cut it. It should have been made of pure aluminum.

 

[crash594]

Was there any signs of something going worng before it happened.

 

[newtek007]

nope

None whatsoever. It just broke off in her hands!

 

[Doubt Incarnate]

is there anything electrical in the colum shifter or could you just put a floor shift in?

 

[newtek007]

yep

There is one wire with a switch that the column activates. I'm not sure what it is, BUT I can tell you that if your not handy with fabrication and and metal, that idea is going to cost you more that just buying the shift column. I don't plan on keeping my truck much longer, so I'm not to worried about it. The wife wants a Honda Odyssey. I've been holding out for the last two vehicles she has owned, so it's my turn to let her get what she wants.

Sorry I can't be much more help though.

 

[bobbydaniel]

Yeah, mine broke off sitting at the drive through at Mcdonalds drive through. Had to get a tow truck to get it home. I've no novice when it comes to fixing things but this was uncalled for. The part can be removed "gear shift assembly tube". But as far as I'm aware nobody sells anything other than whole steering column.
You can drive it by removing plastic housing around column and shift into any gear. I do not advise anyone to do this though it can be done.
You can drive with your feet if you want to, that does'nt make it a good idea.

 

[sharon1962]

Wow someone sent me your post

I just had the same thing happen to me on New Years eve morning and I got lucky it was in park when it broke off. It just cost me almost $1400 to fix this, they replaced the entire steering column. You would think this is a defect and it's something Ford should look into. Unfortunately my car was bought used and the warrenty has long been up.

 

[newtek007]

Sorry to hear it

Wow. As these vehicles get older, this problem is going to happen more frequently. Unfortunately, we haven't been financially able to rid ourselves of this truck, but we are still planning to get rid of it. This vehicle has so many problems it should be illegal.

Our new problem is the 6 disc CD changer. When putting a CD in slot 6, it takes several days for it to eject. Always gets a CD eject error. :thumbdwn:

 

[gigi]

my 2004 explorer gear shift broke off in my hands!

Yeah, mine broke off sitting at the drive through at Mcdonalds drive through. Had to get a tow truck to get it home. I've no novice when it comes to fixing things but this was uncalled for. The part can be removed "gear shift assembly tube". But as far as I'm aware nobody sells anything other than whole steering column.
You can drive it by removing plastic housing around column and shift into any gear. I do not advise anyone to do this though it can be done.
You can drive with your feet if you want to, that does'nt make it a good idea.

mine broke off too!! im so upset, ford said they never heard of this and i have to pay for this, im broke right now,, and my gear shift broke right off in my hands!!!with kids in car,, how much will this cost me??? and should i only take to a ford or can another less expensive auto company help me,, also has any one reported this to BBB?? shouldnt this be a recall??