Ford Escape Hybrid Problems

Abnormal Noise From Driveline on Ford Escape Hybrid

Problem Description and Possible Solution

An abnormal noise may develop from the transfer case. At this time parts are not available to repair internal damage to this type of transfer case, replacement is the only option. It is not uncommon for irregular tire wear to cause a similar noise. Diagnoses should be performed to confirm the actual cause of the driveline noise. Tire noise can be reduced by rotating the tires at least every 5000 miles.

(72 people reported this problem)

Ford Escape Hybrid Vehicles With This Problem

RepairPal Verified
Average mileage: 97,038 (33,000–178,000)
Drive Trains affected: 2WD, 4WD
7 model years affected: 2005, 2006, 2007, 2008, more2009, 2010, 2012
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Viewing 1-20 of 51 comments
Same noise and problem as others described with the transfer case. I do not drive vehicles hard and take very good care of my vehicles. Never off road. Ford dealer quoted $4,400 to replace with a new transfer case. Almost the value of the car.
What an expensive repair! I've been given the option of a new transfer case around 2k or a used one around $800. What a bummer. Like others, I've heard a clunk when in reverse and thought nothing of it. Today on the highway, I wondered if I was going to make it to the repair shop. While the vehicle was on the lift, I heard it for myself. Why isn't Ford stepping up on problems like these?
I successfully sued FORD. Went to the local magistrate and got a judgement against FORD for over $1,500 for the repair of the POWER TRANSFER UNIT. Claimed it was a design defect. Even though FORD had a TSB out on the problem
(throwing our lubricant when traveling down the road) FORD failed to notified its customers affected. With the JUDGEMENT, FORD sent me the check for over $1,500. If you think you are right, take the matter to the local Magistrate!
After front tire wore off to the core, I changed 2 front tires at the dealer.
Right after collecting car the problem happened:

Rubbing(like too metal plates rubbing to
each other) noise from front side ONLY WHEN CAR DECELERATES or REVERSE. The does
not go away for all gear positions (N/D/L), and does not matter the road is smooth or
rough, hard left/right turns etc. However the noise disappears when car accelerates.
Did a check on the hoist, found noise comes from Transfer Case (or PTU as Ford calls it), and was advised to change transfer case.

Changed Transfer Case and so far no issue.
So be careful to rotate and change tires frequently to avoid damaging Transfer Case.
Transfer case failed. Car has been well maintained. Sounds to me like a design flaw. Called to order the part and found its on its tenth redesign. You would think Ford would stand by their product and repair these since it is a design flaw
Heard basically the "tin cans tied under the car" and completely lost power to back up all at once. Have new tires and replaced (supposedly) the Transmission Fluid just months ago. Dealer says Power Take Off unit has to be replaced. I asked what could've caused this - said he has no idea.. Says parts and labor are $1312.44 which sounds better than what others are reporting but also sounds like the dealer or Ford should be taking some responsibility..
Suddenly developed loud noise like dragging tin cans. Took it to AAMCO. They opened the transfer case and reported catastrophic failure of a bearing. New transfer case and labor will run to $1750 plus tax.
Took the car in for a brake check and the dealer told me that the transfer case needs to be replaced because it is leaking. I have experienced a clunk like noise when in reverse but thought that had to do with the regenerative brake system.
Showed up out of literally nowhere. I had just had a bunch of fluids replaced (transmission, differential, power steering) Shortly after I started to hear a strange noise. The issue was it kept changing, one day it would be high pitched and squeal, the next it sounded like a murmur of tire tread, then it wouldn't sound like anything at all. It would be louder when I accelerated and then quieter when it accelerated. I took it to 4 different places and kept getting different answers. At first they said my front brake pads were thin so I got those replaced. Then they told me my tread levels were very different front to rear and that could be creating some noise issues so I had them rotated. Every time they worked on my car it's as if the sound changed and got louder. After about a month of driving and 3 long road trips, a horrible grinding noise arose. It was terrible and concerning, eventually my car started grabbing and pulling while I was trying to drive. Started smelling fluids (probably differential) in the car. I took it in again and it took them (Lithia (STAY AWAY)) 28 hours to diagnose. Bad transfer case and they wanted 4700$ for the fix. I said F that and took my rattle trap home. We have since called LOCAL mechanics around town and found one that says it will be 800$ for the part and 3-400$ for labor. Guaranteed us it won't got over 2,000$ in repairs. That brings us to now, I haven't gathered enough money just yet but will be taking it in in a month or so to have it accurately quoted and then HOPEFULLY fixed. (I just am hoping it isn't going to fall apart on the way to the repair shop.) This has been an ever loving NIGHTMARE and I am FURIOUS that FORD doesn't own up and fix it/reimburse everyone with this issue. In the course of 2 months I have gone from perfectly well maintained and running car to scrap metal and bus riding. I will never buy a Ford again.
We had a whining noise coming from under the car and basically occurred all of the time. I thought it was perhaps a bad CV joint but turned out to be the transfer case. It actually locked up at a stop sign and we had to haul the car home. The car has given us fairly good service over the years but is starting to get expensive to keep going. We haven't decided what to do with the car yet.
rattling noise under vehicle. took in and was told shavings in transfer case. filled oil to level (wasnt empty just low) and will need to replace transfer case. drove home full and still making same noise.
cant afford to fix it i am a senior retired no cash flow the car started making clunk noises when turning then vibrations when using brake one mech said transfer case and another said drive train
not fixed as the cost at the dealer was $4200.00, will I ever buy another Ford ? I think you all know the answer !
Three weeks prior I had put $1,000 into routine service which I thought included all fluids. Started getting this noise and was getting louder. Dealership took my car on short notice and in an hour diagnosed "PTU wear" and gave me the car back without charging. I got two blocks and it sounded far worse than before -- the tin cans dragged under the car. I didn't want to drive it home so left it at the dealer -- they say $3500 for parts and 4 hours of labor at $120/hour.

Drive train warranty died 12,000 miles ago. Car isn't worth $10,000. I'll call Ford and see if they can give me a break on the parts.
Experienced drive train noise next thing I knew it the car broke down and is in operable. I have not fixed the car. It's sitting in my driveway not worth fixing due to the high cost of the repair. This thing is a piece of crap.
Just had 120,000 service, tires rotated for trip to LA. Gets back and forth to LA just fine and clunking noise from right front wheels. Tow it into Ford and they want to charge me $5,000 for a new Power Take Off Unit which according to them is the differential. I still owe 5k on it.
I have no idea what to do.