My Explorer Overheated

[wxman999]

I have had XLT for 15 months now and just dropped of for the fifth time for the overheating/AC issue. This is frustrating. At this point considering investigating lemon law possibilites as I just do not trust the car and that this issue will ever be corrected properly.

 

[aggie76]

Dealer handled it without any questions with the TSB cited. Replaced and seems to be fine now.

 

[wxman999]

Update - allegedly sensor in fan motor assembly was faulty so fans and motor assembly were replaced. Have car back now but was in shop for four days. Double-checked my invoices and this was the fifth visit for same issue. And the second time the entire assembly was replaced. Very disappointed and exploring all options including lemon law.

 

[scottfmc]

My 2011 Limited is going back this week for 2nd instance of this same problem. Last fixed 3-14-12 at 20,961 miles. Very disappointing.

 

[jrmexplorer]

My 2011 Limited is going back this week for 2nd instance of this same problem. Last fixed 3-14-12 at 20,961 miles. Very disappointing.

Have you had the PCM reprogrammed? That is the real fix, not just another fan unit.

 

[scottfmc]

Can't say if PCM reporogrammed as does not appear on work-order, but I will mention it to them - thanks!

 

[IC Smoke]

Add another 2011 to the list of overheating batch.

:thumbdwn: 36,200 miles

 

[peterk9]

Add another 2011 to the list of overheating batch.

:thumbdwn: 36,200 miles

Did you have the 12B36 Customer Satisfaction Program carried out? That is the one where they reprogram the PCM so that the fans will run at a higher speed from time to time to help prevent corrosion etc from building up on the fan motor contacts. That program was free up to May 1, 2013 regardless of mileage.
Even if you had it performed, I guess it doesn't guarantee the fans won't fail. I would speak with the dealer since you are only over the warranty period by 200 miles unless you took out the ESP like many of us did.
If you don't have the extended warranty and the dealer won't cover it under the 3 year, 36,000 mile warranty, they only other option as I see it is to see if either Cory or Crystal (FordCustSrvc) can help out with this issue.
Good luck.

Peter

 

[1995E]

Add another 2011 to the list of overheating batch.

:thumbdwn: 36,200 miles

I'm pretty sure you can argue this with Ford, because I'm not sure if this is covered under your drivetrain warranty which I'm sure everyone has. 60,000 mile 5 year power train warranty. I mean it seems pretty clear you need your fan assembly for the power train to work properly and it's not a normal wear item. Ford knows this is a serious issue, they just didn't label it as a recall, I'm sure if you go towards complaining here:

http://www.safercar.gov/Vehicle+Owners

I think they should go the extra mile to at least fix your issue... since Ford didn't deal with the issue properly and it keeps reoccurring for some people.

 

[IC Smoke]

Thanks gang, We live in a rual area and my wife drives it 50 min one way every day for work so it Its only been in stop and go traffic once or twice and this weekend was the first time it has heated up. I'm going to call my local dealer today. I PM'd Cory Saturday.

The vehicle hasnt been to the dealer for any updates prior to purchase

Thanks! Ill keep ya posted!

 

[TrenchFoot]

My fans quit working at 37,700 miles, just missed the warranty. The dealer wouldn't budge and Ford Customer Service said "Sorry, but no". I PM'ed Cory (FordCustSrvc) who had the regional service manager call me. He had a lot of "Sorry, but no" for me too. (Thanks anyway Cory.)

The service records showed that the fans had been checked at 24k, but the regional service guy insisted that it wasn't a recall, I was on my own and facing a bill for $800 for dealer parts/labor.

I bought the fan assembly from RockAuto (MOTORCRAFT RF273) and when it arrived I couldn't help but assume the module had failed and not both fans. My build date was 5/2011 so I think the fans were updated and not prone to squeaking. I ran a jumper to the battery and both fans ran solid and quiet so I swapped out just the control module (all part numbers on the old and new matched). Total time including testing the fans, disconnecting the battery, and putting away the tools was just 30 minutes. They fired up as soon as I turned the AC on max.

The dealer wanted $800 for this piddily amount of work. The whole fan assembly plus shipping was $230. I couldn't find just the module for sale, but I didn't look very hard. It must be replaceable on its own. If your fans spin after jumpering 12v to them, replace the silver box and tell the dealer to take a hike.

 

[FordService]

...I'm going to call my local dealer today. I PM'd Cory Saturday...

IC Smoke,

I shot you a reply yesterday.

...see if either Cory or Crystal (FordCustSrvc) can help out with this issue...

Thanks for the shout-out, Peter.

...I PM'ed Cory (FordCustSrvc) who had the regional service manager call me. He had a lot of "Sorry, but no" for me too. (Thanks anyway Cory.)...

TrenchFoot,

You got it. I wanted to make sure it was reviewed for you.

Cory

 

[WOLFexplorer]

Im getting the same thing on my 2011 Limited with 15k miles on it. On really hot days, Engine overheat warning came on once

 

[hottdogg]

My fans quit working at 37,700 miles, just missed the warranty. The dealer wouldn't budge and Ford Customer Service said "Sorry, but no". I PM'ed Cory (FordCustSrvc) who had the regional service manager call me. He had a lot of "Sorry, but no" for me too. (Thanks anyway Cory.)

The service records showed that the fans had been checked at 24k, but the regional service guy insisted that it wasn't a recall, I was on my own and facing a bill for $800 for dealer parts/labor.

I bought the fan assembly from RockAuto (MOTORCRAFT RF273) and when it arrived I couldn't help but assume the module had failed and not both fans. My build date was 5/2011 so I think the fans were updated and not prone to squeaking. I ran a jumper to the battery and both fans ran solid and quiet so I swapped out just the control module (all part numbers on the old and new matched). Total time including testing the fans, disconnecting the battery, and putting away the tools was just 30 minutes. They fired up as soon as I turned the AC on max.

The dealer wanted $800 for this piddily amount of work. The whole fan assembly plus shipping was $230. I couldn't find just the module for sale, but I didn't look very hard. It must be replaceable on its own. If your fans spin after jumpering 12v to them, replace the silver box and tell the dealer to take a hike.

Trenchfoot I'm in the same boat as you car out of warranty and dealer wanst $900 to do it, did you have to take your car to the dealer for any kind of programming?

 

[TrenchFoot]

There's no need to visit the dealer, swapping out that relay module was easier/faster than changing a tire. Even knowing that some reprogramming was done to alter fan speeds, I suspect that's all in the main computer, whatever Ford calls it. Out of curiosity I cracked open the old module and it's got small circuit card in it, but I doubt the 'reprogramming' changes the firmware in that box. I think it's more likely that they just change the commands/signaling that is sent to it from the main ECU.

The service coordinator at the dealership helped me out by giving me the part number for the whole assembly: ba8z8c607c. From looking at various ones for sale online, there may be a different one if you have the tow package (mine didn't) or a build date after ~10/2011. In the end, I don't think the relay assembly is different, they all end up being called Motorcraft RF273.

If the fans don't spin, that box isn't doing you any good anyway so just take it out so you can compare part numbers and hunt online. I wouldn't buy they whole fan/shroud/relay package like I did, just replace that silver box if you can. If it's unavailable to buy separately, you can get the whole shooting match off RockAuto cheaper than anywhere else.

In theory, changing out the shroud assembly isn't difficult but it looked to me that it'd slide out the bottom easier than lifting it up, but you may end up having to disconnect one or both radiator hoses either way. I wasn't looking forward to putting it up on stands or driving to a friend's house with a lift. That shroud is over 20" tall, so lifting it out might be easier if you don't have access to a lift.

Bottom line, if they don't spin with the AC on max I'd suspect the relay module. Test your fans with a couple jumper wires to their plugs and if they spin I'd pull the relay module then find the easiest, cheapest way to replace it. I suspect you can drive with it out since my Explorer's computer didn't know it was blown anyway (for months likely).

After I replaced mine the car fired up, reset Sync (because the battery was disconnected) and once I hit max AC I knew the dealer wasn't going to get $800 out of me.

Good luck, here's a pic of the old and new relay module (everything on the labels is identical). Maybe the part numbers will help someone out. It's installed upside down from what's shown below. Disconnect the three connectors and use a torx bit to remove the one screw holding it in, tilt it down and lift it out.

 

[peterk9]

There's no need to visit the dealer, swapping out that relay module was easier/faster than changing a tire. Even knowing that some reprogramming was done to alter fan speeds, I suspect that's all in the main computer, whatever Ford calls it. Out of curiosity I cracked open the old module and it's got small circuit card in it, but I doubt the 'reprogramming' changes the firmware in that box. I think it's more likely that they just change the commands/signaling that is sent to it from the main ECU.

The service coordinator at the dealership helped me out by giving me the part number for the whole assembly: ba8z8c607c. From looking at various ones for sale online, there may be a different one if you have the tow package (mine didn't) or a build date after ~10/2011. In the end, I don't think the relay assembly is different, they all end up being called Motorcraft RF273.

If the fans don't spin, that box isn't doing you any good anyway so just take it out so you can compare part numbers and hunt online. I wouldn't buy they whole fan/shroud/relay package like I did, just replace that silver box if you can. If it's unavailable to buy separately, you can get the whole shooting match off RockAuto cheaper than anywhere else.

In theory, changing out the shroud assembly isn't difficult but it looked to me that it'd slide out the bottom easier than lifting it up, but you may end up having to disconnect one or both radiator hoses either way. I wasn't looking forward to putting it up on stands or driving to a friend's house with a lift. That shroud is over 20" tall, so lifting it out might be easier if you don't have access to a lift.

Bottom line, if they don't spin with the AC on max I'd suspect the relay module. Test your fans with a couple jumper wires to their plugs and if they spin I'd pull the relay module then find the easiest, cheapest way to replace it. I suspect you can drive with it out since my Explorer's computer didn't know it was blown anyway (for months likely).

After I replaced mine the car fired up, reset Sync (because the battery was disconnected) and once I hit max AC I knew the dealer wasn't going to get $800 out of me.

Good luck, here's a pic of the old and new relay module (everything on the labels is identical). Maybe the part numbers will help someone out.

Just FYI. Fordparts.com lists RF273 as costing $437.20.

Peter

 

[FordService]

Im getting the same thing on my 2011 Limited with 15k miles on it. On really hot days, Engine overheat warning came on once

Have you visited your dealer to check it out, WOLFexplorer? I can help by setting up a call from your regional customer service manager. For me to do this, please shoot me a PM with your full name, VIN, mileage, best daytime phone number, and dealer info.

Trenchfoot I'm in the same boat as you car out of warranty and dealer wanst $900 to do it...

hottdogg,

I see you were in touch with Jen today; she scheduled you a follow-up call. Don’t hesitate to send me any details you want forwarded before then.

Cory

 

[IC Smoke]

Cory
Its greatly appreciated!!! she called but were out of the warranty. I'm going to take it in to be updated. If that doesn't fix it I'll be doing some wrenching!

 

[plumbago]

Just FYI. Fordparts.com lists RF273 as costing $437.20.

Peter

I think that's the whole motor and fan assembly not the Relay...../

 

[peterk9]

I think that's the whole motor and fan assembly not the Relay...../

That's correct. hottdogg said the dealer wanted $800 for it and he got for $230 with shipping.

Peter