how to fix Ford Explorer Fifth Generation (2011-2019) rear differential noise

Ford Explorer Fifth Generation (2011-2019)

Error Codes

3-5 hours

Time

medium

Difficulty

medium

Severity

4 min read

603 words

Problem Statement

Learn how to diagnose and fix rear differential noise in Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Suspension

Estimated Time

3-5 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Always use jack stands to support the vehicle when working underneath.
•Allow the differential to cool if it has been recently driven to prevent burns.

Symptoms

•Grinding or whining noise during acceleration or deceleration
•Clunking sounds when turning corners
•Vibration felt through the vehicle when driving
•Fluid leakage from the differential
•Unusual wear patterns on tire tread

Diagnostic Steps

1
Inspect the rear differential fluid level and condition; look for metal shavings or discoloration.
2
Check for leaks around the differential housing and seals.
3
Listen for noise while the vehicle is stationary; check if it changes with wheel rotation.
4
Lift the rear of the vehicle and manually rotate the wheels to identify any irregular sounds.
5
Inspect the U-joints of the drive shaft for wear or damage.
6
Use a stethoscope to pinpoint the source of the noise in the differential.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•Jack and jack stands
•Socket set
•Torque wrench
•Fluid pump

Parts Required

•Differential fluid (as specified in owner’s manual)
•New differential bearings (if needed)
•Differential cover gasket or RTV sealant

Related Faults

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Diagnostic Steps

1
Inspect the rear differential fluid level and condition; look for metal shavings or discoloration.
2
Check for leaks around the differential housing and seals.
3
Listen for noise while the vehicle is stationary; check if it changes with wheel rotation.
4
Lift the rear of the vehicle and manually rotate the wheels to identify any irregular sounds.
5
Inspect the U-joints of the drive shaft for wear or damage.
6
Use a stethoscope to pinpoint the source of the noise in the differential.

Solution

1. Preparation

Tools Required: Jack and jack stands, socket set, torque wrench, fluid pump, differential oil.
Place the vehicle on a flat surface, engage the parking brake, and lift the rear using a jack. Secure with jack stands.

2. Drain Differential Fluid

Locate the differential drain plug.
Using a socket, remove the drain plug and allow the fluid to completely drain into a suitable container.
Inspect the drained fluid for metal shavings or contaminants.

3. Remove Differential Cover

Clean any dirt around the differential cover bolts to prevent contamination.
Remove the bolts securing the differential cover using a socket.
Carefully pry off the cover using a plastic scraper to avoid damaging the mating surface.

4. Inspect Internal Components

Check the condition of the ring and pinion gears for wear or damage.
Inspect the differential bearings and races for signs of wear or pitting.
Rotate the gears to feel for roughness or binding.

5. Replace Bearings and Seals (if necessary)

If bearings are worn, use a bearing puller to remove them from the differential case.
Clean the bearing seats and install new bearings using a press or appropriate tool.
Replace the differential side seals to prevent future leaks.

6. Reassemble and Fill with New Fluid

Clean the differential cover mating surface thoroughly.
Apply a thin bead of RTV silicone or use a new gasket to seal the differential cover.
Reattach the cover and securely fasten the bolts to the manufacturer's torque specifications.
Fill the differential with the recommended fluid using a fluid pump until it reaches the fill level.

7. Test Drive

Lower the vehicle and take it for a test drive to ensure the noise is resolved.
Monitor for any unusual sounds or leaks.