2003 Expedition rear differential problem - Ford Forums

klandry · 07-07-2003, 12:36

I recently bought a 2003 Ford Expedition and I'm having a strange vibration coming out of the rear differential. It almost feels/sounds like the rumble strips on the sides of highways. It seems to only happen in the morning or after it has been sitting for a long period of time. I notice it only when I make a sharp turn from a stop and accelerate. It goes away after about 5 minutes of driving.

The dealer has looked at it several times. Through vibration tests they have determined it is coming from the rear differential and are suspecting it is the limited slip. Upon the recommendation of Ford Engineering, they replaced the rear fluid with a different synthetic and asked me to drive it for another couple thousand miles to see if it makes any difference.

Anyone else having similar trouble?

-Ken

LunaticSVT · 07-07-2003, 15:06

The noise you described can be caused by a worn ring and pinion gear in the differential. With your truck under warranty still I would approach the dealership again. Ask them if they added the recommended friction modifier. Without this it will reoccur and damage the components.

responded to other post as well.

scottf200 · 08-05-2003, 17:41

FYI, the dealer I bought my used '03 Expedition from fixed the differential based on a TSB. I'm afraid they didn't tell me anymore details that I can recall. It was before I got it.

4rdfan · 01-05-2004, 04:01

I have a 2003 Expedition that had the same noise you described from the rear end, this occurred at 9K. The dealership replaced the ring and pinion gears and the noise has stopped, currently I have 12K on it, I'm hoping that it was a one time fix and don't have a repeat problem. Other than oil changes, this is the only reason my Expedition has been in the shop.

V8Edy · 03-27-2004, 07:42

I have a 1998 V8 Rear-wheel drive Explorer and have been feeling the same vibration. I was intending to take to the dealership on Monday but was worried about the cost of such a repair. Do you guys know how much it could cost? I am a poor college student... BTW new to the forum here, seems awesome... Edy

LunaticSVT · 03-27-2004, 10:42

Not sure on the cost persay. Most work that I have had done has been underwarranty or as a TSB replacement issue with no cost associated.

roybus14 · 04-05-2004, 05:36

I've got a very similar problem but it is appears to be coming from the front. When we take the truck out of the garage or move it after sitting for a while, we get the rumble-strip noise when turning the wheel to the left or right and stepping on the Gas. But the problem seems to go away after about 15-20 minutes of driving or when the truck is warmed up. I have a 2004 XLT (Purchased new on 02-28-04). I am taking it to the dealer this weekend to have them take a look at this problem. I will be sure to include the forum's thoughts on this problem when speaking with the dealership this weekend...

I am happy to be a part of this forum so that we can all share this information. thanks....

gwinnch · 01-05-2005, 05:03

I have an '03 Expedition and experienced the same noise when first driving in the morning. I bought access to my vehicles TSB's & Recalls at motorcraft.com. (I think it's 20 bucks for a month) and saw one about the limited slip differential: It talks about the noise & suggests trying new fluid then replacing the clutch pack if that doesn't work. My dealer replaced the clutch pack under warranty after I showed him the TSB. That was 6 months ago. Now the noise is back & I'm taking it back in. All kinds of interesting info. at motorcraft to help get your warranty work done before it runs out.

OlSkool · 01-05-2005, 20:59

Quote:

Originally Posted by gwinnch

I have an '03 Expedition and experienced the same noise when first driving in the morning. I bought access to my vehicles TSB's & Recalls at motorcraft.com. (I think it's 20 bucks for a month) and saw one about the limited slip differential: It talks about the noise & suggests trying new fluid then replacing the clutch pack if that doesn't work. My dealer replaced the clutch pack under warranty after I showed him the TSB. That was 6 months ago. Now the noise is back & I'm taking it back in. All kinds of interesting info. at motorcraft to help get your warranty work done before it runs out.

ok well since it looks like sooo many of you have this problem, and since i have access to alldata, i will check tommorrow on any TSB, and Recalls print it out and post it on a sticky on this Forum.

ck535 · 02-08-2005, 14:34

I bought a new 2003 expedition. It developed a vibration and leak at the differential seals where the axles enter the differential which resulted in replacement of the seals both sides and ring gear/ pinion gear @15k. At 30k the same problem developed and again the seals ring gear/pinion gear were replaced again. I questioned this and asked for an extended warranty which no one would help with. I was told that this is an occaisional problem and that the first repair did not work because they redesigned the seals and that the 2nd repair had the new type seals. Each of these repairs cost in the $800 range under warranty so I am told this would be much more expensive as a consumer, the dealer provided a rental car but they had the car for five days each time. I just left the car off at the dealers with 32k for replacement of the newly redesigned and installed rear differential seals that are again leaking. I was told that Ford will replace gears if after the seal is replaced my car is noisier than others with similiar mileage.
I also get an intemittent noise from the front of the car 30-40mph and 60-70mph that sounds like the car needsto shift ot a highger gear. I cannot always reproduce this but read someon else that it occurs only when cold.