WARNING to all late model owners...

[borderchris]

Hey all- I had originally posted a thread seeking opinions on a whining rear end on my '03 XLT, and per those reccomendations I went in to the dealer today. After they drove it, they heard the whine at 60+. Then they popped off the rear cover, and lo and behold, less than a quart of fluid came out, and absolutely fried ring, pinion, carrier bearings and, well, everything!

Note to all- CHECK YOUR FLUID LEVEL! The parts are going to take a week to get here from Detroit. The good news is that Ford says the entire differential assembly must be replaced, including the case and U-Joints to the axle shafts due to overheating.

Why they send out new $30,000 vehicles with insufficient rear gear oil is absolutely beyond me, since the warranted cost will be over $1800...

 

[Rick]

Sorry to hear that. I've heard of that type of thing happening before in other vehicles. I beleive the dealership is supposed to check all fluid levels before delivery, so yes it was the factory's fault in the first place, but it may have been an over zealous dealer that let the inspection slide so they could get the truck up for sale on the lot quicker.

 

[spindlecone]

Just as I said yesterday, my friends was bone dry 04, 40 miles it went south, when he picked up his S.T, after it had been compleatly prepped by the dealer, he drove it back to work, I than took her for a test run, shut it down and told him to call the dealer, they came and picked it up, My 03 S.T. was low on lube, way low, but no problems thank god as it will never be covered under warranty

 

[borderchris]

And another interesting thing- I heard the SA talking to the Ford zone rep on the speaker phone, and (conspiracy theories aside) and the rep was not the least bit shocked, and even referred to a service bullitin, although the SA stated that such a bullitin was not a public one. In other words, they wait and hope that most people don't notice the fluid-starved whine, and hope even more that the differential doesn't sieze until after 36,000 (word for word fromt the SA!).

That's nice.

 

[Rick]

I bet I know what happened... If you fill a bone dry axle to the "fill line" you are still a quart or more low since the oil hasn't had a chance to fill up in the axle tubes... I have had that happen after having new gears installed in my Explorer. Thing is... I'm so **** I check my fluids any time they have had the cover off so I only drove 10 miles to my house before checking it. I don't trust anyone

 

[Robb]

Axle tubes on an '03?

 

[Rick]

Axle tubes on an '03?

LOL, what was I thinking... Unless it's a Sport that is.

 

[unclemeat]

I have heard from anothe gen III owner who was on his third rear end that it has become a common problem and the Ford engineers dont know how to fix the problem. I believe that if excessive heat is occouring in the differential that the oil will volitalize (evaporate), thus creating a low oil condition. I would ask a few more questions at the dealership. Was the level low because of improper filling or was it something else. And what is the warrenty following the repair.

 

[B767capt]

I just drove my kids 02 explorer the other day for the first time in a while and I immediately heard a whine. They didn't notice it. I checked the magnetic plug and about a 1/2 a quart came out. The rear end was cold and the vehicle was pointed slightly down hill. Seemed over full. Anyway the oil was black and I replaced with new and will see what will happen. The mag plug was at max capacity as far as metal filings on it. It has 33k for miles.