Having been the recent victim of a design flaw, I guess I'm wondering the
same thing. The transmission in my wife's 2003 Explorer lost 2nd gear and
overdrive, the O/D Off light blinking and eventually causing the Check
Engine light to illuminate. Since it has 75,000 miles and is out of
warranty, I took the advice of a friend and brought it to a local
transmission shop. He echoed exactly what I found on the internet - Ford
decided to save a few bucks by just boring some holes into the aluminum
housing to accept some shafts, rather than bushing them with bronze. A $2200
rebuild to fix a design flaw. This apparently is a well-known and common
problem on 2002-2004 Explorers, but Ford refuses to help, since they are no
longer covered by warranty. I intend to file a complaint with NHTSA. My
co-worker's 2000 Toyota Tacoma, however, was bought back at 150% of what it
was worth on it's best day because the frame rotted out, long after the
warranty ran out. I'm still wondering why that wasn't a recall.

Bill

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