my Ford Explorer's rear differential is making noise what's the fix

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

538 words

Problem Statement

Learn how to diagnose and fix noise in the rear differential of your Ford Explorer. Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Suspension

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Ensure the vehicle is securely supported before working underneath.
•Allow the differential to cool before draining fluid to avoid burns.

Symptoms

•Grinding or whining noise when accelerating or decelerating
•Clunking sound during turns
•Vibration felt in the rear of the vehicle
•Difficulty in engaging or shifting into four-wheel drive
•Fluid leaks around the differential housing

Diagnostic Steps

1
Inspect the rear differential fluid level and condition.
2
Check for any visible leaks or damage to the differential housing.
3
Listen for noise while the vehicle is in motion to determine when the noise occurs (acceleration, deceleration, or turning).
4
Inspect the universal joints and driveshaft for wear or damage.
5
Use a stethoscope or mechanic's listening device to pinpoint the noise source.
6
Perform a visual inspection of the differential gears and bearings if accessible.

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
•Jack stands
•Wheel chocks
•Socket set
•Torque wrench
•Differential fluid
•Cleaning rags

Parts Required

•Differential cover gasket or RTV sealant
•Ring and pinion gears (if worn)
•Differential bearings (if worn)

Related Faults

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Diagnostic Steps

1
Inspect the rear differential fluid level and condition.
2
Check for any visible leaks or damage to the differential housing.
3
Listen for noise while the vehicle is in motion to determine when the noise occurs (acceleration, deceleration, or turning).
4
Inspect the universal joints and driveshaft for wear or damage.
5
Use a stethoscope or mechanic's listening device to pinpoint the noise source.
6
Perform a visual inspection of the differential gears and bearings if accessible.

Solution

1. Preparation

Tools Required: Jack, jack stands, wheel chocks, socket set, torque wrench, differential fluid, cleaning rags.
Raise the vehicle securely using a jack and support with jack stands.
Ensure the vehicle is on a level surface and the rear wheels are chocked.

2. Drain Old Differential Fluid

Place a drain pan under the differential.
Remove the differential cover bolts using a socket set.
Carefully pry off the cover and allow the old fluid to drain completely.
Inspect the inside of the differential for metal shavings or debris.

3. Inspect and Replace Components

Check Gears and Bearings: Inspect the ring and pinion gears for wear, pitting, or damage. Check the bearings for smooth rotation and signs of wear.
Replace Components if Necessary:
- If gears or bearings are worn, replace them with manufacturer-specified parts.
- Remove the old bearings using a bearing puller.
- Install new bearings and ensure they are properly seated.

4. Clean and Reassemble

Clean the differential cover and the housing mating surface thoroughly.
Apply a new gasket or RTV sealant to the cover.
Reattach the differential cover and torque the bolts to the manufacturer's specifications.

5. Refill Differential Fluid

Fill the differential with new fluid using a funnel until it reaches the fill plug level.
Ensure to use the correct type of differential fluid as specified in the owner’s manual.