Re: 2004 Explorer Rear End Problems (X6)
Here is an update on this situation. I went to the dealer and got to see the rear end totally disassembled and all the new parts.
The rear end is going to be completely replaced, this time with a new housing as well. They found a broken retaining clamp this time. Not sure of the exact name of the part, but I would describe it as a retaining clamp in two parts held together by two bolts through one half of it. It is about 3" circular and is in two parts normally, an upper 1/2 circle with two bolts on each end and a lower 1/2 circle that receive the bolts. The part that broke is right near one of the top bolts. Being that the part is aluminum, they are blaming it on a bad casting. All new bearings are also being installed.
A couple of interesting notes.
The same repair was done on another Explorer the day before. Service writer said that with this type of major repair under Extended Warranty, Ford ususally sends out an inspector but they now just authorize the repair. Tells me that it is a re-occuring problem at best.
I hope if it is going to fail again it does so in the next 7000 miles so it is covered under the Extended Warranty or will be covered under the 12mo/12,000 mile warranty.
I am surprised that with all the Explorers on the road that there are not more reports of this problem. ??
I got a response from the Ford Customer Relations Center from my email to them detailing the saga of 6 repairs/replacements of the rear end on the same Explorer. Here is their response (or non-response as I consider it). Can hardly wait for the call from the Service Manager to see what he has to say.
I am documenting your concerns and your information will be sent to your Dealership. Your Service Manager is in the best position to assist and should contact you within 4 business days.
Sometimes e-mail communication does not allow us to gain additional information that may be helpful in responding to your inquiry. Should you feel that we have not adequately addressed your questions, please feel free to contact us via telephone at (800)392-3673 between the hours of 8am and 5pm, local time, Monday through Friday. Hearing-impaired callers with access to a TDD may contact 1-800-232-5952. Please provide your 10 digit reference number - 0422042757.
Customer Relationship Center
Ford Motor Company