OSCILLATING HUMMING NOISE/VIBRATION AT HIGHWAY SPEEDS, GOES AWAY IN 4H

[Milmand]

Thankfully the dealership I've been dealing with hasn't been giving me any trouble and are willing to figure out this issue (for now).

That being said they first stated the noise was coming from the FAD not disengaging properly so they replaced it. However the vibration/noise was still present after that replacment and they then decided to replace the front diff because they found metal particles in the fluid. The noise was still present after that swap too. So now they're claiming it's the transfer case as they've also found metal shavings in the ATF. It's currently in the shop having a complete tear down of the transfer case.

I don't have much faith this will solve the problem either. I'm about ready to trade it in.

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[Joshz]

Is anyone having this issue with the SAS package and the M210 front axle. I have had the same vibration close to day one with my 2023 Wildtrak. I have had it back to the dealer twice to rebalance my tire, the 3rd time they said it was just how 35’s are supposed to be. I mention my 22 Badlands SAS never had this issue. Happens over 45, it can be felt mostly when decelerating on the highway at speed.

 

[Fly]

Is anyone having this issue with the SAS package and the M210 front axle. I have had the same vibration close to day one with my 2023 Wildtrak. I have had it back to the dealer twice to rebalance my tire, the 3rd time they said it was just how 35’s are supposed to be. I mention my 22 Badlands SAS never had this issue. Happens over 45, it can be felt mostly when decelerating on the highway at speed.

I have an intermittent grinding/vibration sound that happens over 45mph on SAS when in 2H or 4A. It comes and goes lasting a second at a time, but you can feel it on the floorboard with your foot. This goes on for a month or so then goes away for a month or so.

While it was happening I pulled off into a dirt lot, put it in 4L and drove around a few mins. Went back on the highway in 2H and the sound went away. Dealer checked it out and said it is just the Goodyear tires making noise (it isn’t).

 

[Silver-Bolt]

I have seen a couple of reports where it turned out to be the rear axle bearings. I notice it most from 55mph-65mph. Above 65mph it starts to go away. By 70-ish it's gone.

 

[OIFtanker4thID]

I am having this same problem. It’s like when I go 55-60 it rhythmically vibrates and goes vrrrt … vrrrt and I can feel it on the floor board and it’s like it doesn’t coast or disengage when I let off the gas. It started at around 10k miles.

 

[aaronmrandolph]

Having the same issues. I have a 2023 Lifted Outer Banks. The lift, tires, and wheels all came custom from a custom dealer that specializes in custom work. Drove it for 4-5 months with no issues then on our first snow storm back in December we put it into 4H. Once i took it out of 4H the oscillating vibration at the front axel started. It only happens in 2H and goes away in 4H. I've been to three dealers, all blamed it on the lift. Then i took it to an axel specialist (Axel Boy) they put this sensor on the axel and you can see/hear the vibration go away in 4H and come back in 2H. We submitted the info back to Bo Beuckman Ford who agreed it has to be a factory issue with the actuator however when they contacted Ford for a replacement axel (because they make them as one piece) Ford denied it and said it had to be the lift. So far i am about 5 months in and no solution.... not sure what to do.

 

[andersman02]

Having the same issues. I have a 2023 Lifted Outer Banks. The lift, tires, and wheels all came custom from a custom dealer that specializes in custom work. Drove it for 4-5 months with no issues then on our first snow storm back in December we put it into 4H. Once i took it out of 4H the oscillating vibration at the front axel started. It only happens in 2H and goes away in 4H. I've been to three dealers, all blamed it on the lift. Then i took it to an axel specialist (Axel Boy) they put this sensor on the axel and you can see/hear the vibration go away in 4H and come back in 2H. We submitted the info back to Bo Beuckman Ford who agreed it has to be a factory issue with the actuator however when they contacted Ford for a replacement axel (because they make them as one piece) Ford denied it and said it had to be the lift. So far i am about 5 months in and no solution.... not sure what to do.

Unfortunately, at this point I think your kind of SOL unless you want to threaten the magnuson-moss law. However because your lifted with bigger tires you may be SOL even if it's not the reason for failure (which I don't think it is)

You could swap to a 210, or even possibly just try disconnecting the harness, at the actuator. That may leave it in a always connected state

 

[aaronmrandolph]

Quick update here - took the bronco in for routine oil change with my local mechanic. He inspected it and noticed my front struts were leaking. Called the old dealership and they never returned my call so I called the only other ford dealer in my area and got it in yesterday. I told them about the front struts and the vibration. They did diagnostics and called to confirm they are replacing the front struts and found the vibration was the actuator disconnect malfunction which requires a full axel replacement. They said it should all be wrapped up today or tomorrow. When I go get it I’ll get more detail from them on how they were successful when all the others failed. And I’ll pass along any details I can get from them.

 

[aaronmrandolph]

Update here - after a total of two months of the Bronco being in and out of four shops (three dealerships), we think we have it fixed. See the attached image of my invoice.

Technician was skilled enough and cared enough to keep investigating while no DTCS codes were present (this is where other dealers fail to continue investigating in my opinion).

Clutch in actuator was staying partially engaged. Ordered and replaced axle disconnect actuator. Tested and problem was still present.

Suspected worn differential bearings in front axel, compared to like unit and not normal.

Removed drain plug from front axle and found excessive metal in fluid.

Ordered new axel, replaced and tested and vibration is gone.

So far so good, just got it back and will see how long she lasts.

Hope this helps.

Aaron

 

[dave91gt]

Add me to the club. Just bought a 24 OBX SAS and drove it on a 200-mile trip yesterday. It's my wife's daily driver so I have had limited time in it so far. Just hit 1K miles. I've had several lifted vehicles and can discern between driveline and tire imbalance. Unfortunately, ours has both issues. The driveline hum starts just around 60 mph and is most pronounced up to around 70/75 mph where the tire imbalance becomes the more noticeable of the two. I'm not worried about the tire balance. But driveline vibrations can really be difficult with a dealer. Been there before. The Bronco had no vibes on test drive or drive home from the dealer (60 miles). Noted the tire balance to the dealer for a future visit. It's a lifted SUV with 35" tires- I don't expect luxury. But haven't told them yet about the new noise. I have a great dealer so I know I can get something done. This thread will help narrow it down, I hope. We haven't wheeled it or even taken it offroad. But I have played around with the 4x4 in the driveway learning the various features. And I believe that was the trigger for the noise. Maybe it hasn't disengaged?

 

[aaronmrandolph]

That would seem to align with issues I had. All started the first time I used 4X4.

take a snap shot of what my dealer did and that should be a good start.

good luck!

 

[Ford Motor Company]

Add me to the club. Just bought a 24 OBX SAS and drove it on a 200-mile trip yesterday. It's my wife's daily driver so I have had limited time in it so far. Just hit 1K miles. I've had several lifted vehicles and can discern between driveline and tire imbalance. Unfortunately, ours has both issues. The driveline hum starts just around 60 mph and is most pronounced up to around 70/75 mph where the tire imbalance becomes the more noticeable of the two. I'm not worried about the tire balance. But driveline vibrations can really be difficult with a dealer. Been there before. The Bronco had no vibes on test drive or drive home from the dealer (60 miles). Noted the tire balance to the dealer for a future visit. It's a lifted SUV with 35" tires- I don't expect luxury. But haven't told them yet about the new noise. I have a great dealer so I know I can get something done. This thread will help narrow it down, I hope. We haven't wheeled it or even taken it offroad. But I have played around with the 4x4 in the driveway learning the various features. And I believe that was the trigger for the noise. Maybe it hasn't disengaged?

Good morning! I would be glad to help you out with vibration concerns should you need further assistance. Just shoot us a PM with your VIN and dealer name/location, and I'll get right on it. To send a private message, just click on our username and select "Start Conversation". Thank you!

 

[RunningJerk]

Update here - after a total of two months of the Bronco being in and out of four shops (three dealerships), we think we have it fixed. See the attached image of my invoice.

Technician was skilled enough and cared enough to keep investigating while no DTCS codes were present (this is where other dealers fail to continue investigating in my opinion).

Clutch in actuator was staying partially engaged. Ordered and replaced axle disconnect actuator. Tested and problem was still present.

Suspected worn differential bearings in front axel, compared to like unit and not normal.

Removed drain plug from front axle and found excessive metal in fluid.

Ordered new axel, replaced and tested and vibration is gone.

So far so good, just got it back and will see how long she lasts.

Hope this helps.

Aaron

Do you have an update on this? Did your problem completely go away?

 

[SpicyBronco]

Good morning! I would be glad to help you out with vibration concerns should you need further assistance. Just shoot us a PM with your VIN and dealer name/location, and I'll get right on it. To send a private message, just click on our username and select "Start Conversation". Thank you!

Do you have an update on this? Did your problem completely go away?

Coming in 2025 with the same issue… was it the actuator that ended up being the solve? I’m wary of the dealership closest to me. I also can’t send a PM to the Ford official account to see if they have any advice.

 

[andersman02]

Imo I would self diagnose, going as far as disconnecting the pig tail connection for the actuator, before bringing it in. You really need to pin point it for the techs on this one

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