Dealership found metal chunks in rear end just before Oregon trip

[jdoxen]

Around 2 weeks ago I took my Bronco (2023 base manual 2dr) in for its 30,000 mile service, which is the first major service where they do more than change the oil and top up the washer fluid. It had been driving great and not making any noise, so I was surprised when later that afternoon I got a call from the advisor saying they found "metal flakes" or "shavings" (I forget his exact wording) on the rear diff drain plug. I haven't seen the damage with my own eyes so I don't know how bad it is. A cursory look online suggests that fine powdery shavings is normal wear, but any larger chunks are bad news. He recommended replacing it while the vehicle was still under warranty to save me 3-4 grand. Unfortunately the parts they need have, in his words, "no ETA" so they're just hanging onto my Bronco indefinitely until they can repair it. In the meantime, they've given me a Mustang convertible as a loaner (it was the only other Ford available that day at the local Enterprise, apparently).

If I were only planning to commute during that time, I'd be fine this this arrangement. A bright yellow muscle car isn't really my style, but it does all the car things a car needs to do on the daily drive. However, I'm planning to drive from where I live in the Bay Area up to Oregon this coming Saturday, a trip I've been planning for months and would really not like to cancel. I am expecting to encounter some snow on my route and was counting on having the Bronco's 4WD to get me through if things got hairy. I mean we're not exactly talking Ice Road Truckers here, but better safe than sorry... Only now I'm stuck with a car that has, charitably, a very different set of capabilities.

So, what would you do in this situation? Time is running out to make a decision. Do you think they're right to nip this in the bud while it's still under warranty? Or are they making a bigger deal out of normal wear than they need to, and I should just have them change the fluid as normal and give my Bronco back? If I do have them go through with the repair, will I have any success pestering them to give me a loaner with a skill set closer to the vehicle I actually bought? Any advice is appreciated.

UPDATE so you don't have to hunt through the rest of the thread: What was at first described to me as "metal flakes/shavings" turned out to be big chunks, I don't know exactly what part they broke off of but it definitely wasn't an overreaction to stop driving the Bronco and let them replace the rear end under warranty. Have a look for yourself.

As of writing they will apparently have the new rear end assembly in tomorrow (and that's surprising since some people have been waiting months for the same part), but they likely won't finish installing it before I leave. The consensus as far as the loaner seems to be "people still buy Mustangs back east" so I'm just going to put the miles on their car and pick up the Bronco when I get home.

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[Ducati1098]

If they didn't find some metal shavings or flakes on the rear diff drain plug, then i'd probably be concerned lol
A small build up of material is completely normal That being said, I can't see what it actually looks like.

But I mean if they want to replace something you weren't even complaining about or had a concern about, well then let them I guess?

I certainly wouldn't let them hold onto the vehicle if they ordered a whole new rear axle assembly, those are known to take MONTHS to receive since they are built to order.

 

[arwhite]

Can you drive your Bronco on your trip and do the warranty service after your trip? Do they really need to hang on to it while waiting for parts? I mean, it doesn't sound like it's at the point of impending failure.

 

[jdoxen]

I certainly wouldn't let them hold onto the vehicle if they ordered a whole new rear axle assembly, those are known to take MONTHS to receive since they are built to order.

Oof that's what I was worried about. I guess my question is really, do you think it's safe to keep daily driving for that many months? The advisor talked about it as if it could fail at any time, but then again he's not the actual mechanic doing the dirty work. I wish I'd asked for a picture when they first told me about it.

Nice Ducati by the way

 

[BigBend530]

If the dealership is telling you it is unsafe to drive then they should be providing you a loaner vehicle for the time your Bronco is stuck at the shop until it has been repaired.

This might require a call into Cuatomer Relations to encourage getting you a vehicle to use while yours is stuck at the dealership in an "unsafe to drive" condition.

 

[jdoxen]

If the dealership is telling you it is unsafe to drive then they should be providing you a loaner vehicle for the time your Bronco is stuck at the shop until it has been repaired.

This might require a call into Cuatomer Relations to encourage getting you a vehicle to use while yours is stuck at the dealership in an "unsafe to drive" condition.

They did give me a loaner, it's just that it's a convertible Mustang which isn't going to serve me very well in the snow. I asked if they had anything else but it was the only Ford (policy dictates it had to be another Ford) they could give me that day.

 

[Brian_B]

It's totally normal for there to be metallic sludge in the oil - like sand.

It's not normal for there to be shavings like sawdust or BBs

 

[BigBend530]

They did give me a loaner, it's just that it's a convertible Mustang which isn't going to serve me very well in the snow. I asked if they had anything else but it was the only Ford (policy dictates it had to be another Ford) they could give me that day.

I would follow up and tell them you need a similar vehicle as what is in the shop because you had travel plans that cant be rescheduled. When my Bronco was in the shop (bad PCM on day 1), I got a loaner that was a brand new Explorer XLT is barely 30 miles on it.

 

[B22-2023]

If you didn’t notice it, and no matter what was found on the little magnet, if the housing is lubed up full then I don’t see why it should sit at the dealer that long and you not drive it. It’s not like they said “chunks of entire teeth“ came out - and that magnet can hold what, a tablespoon of “shavings“ which is largely gunked up lube oil anyway. Everyone gets this it seems, many including me just a few thousand miles after delivery.

Tell them you need the truck and you know it’s a built-to-order part, then call you when it comes in. Most dealers in large metros don’t want vehicles sitting on site that long anyway. Throw a supplemental magnet on the housing too if that makes you feel better.

 

[jdoxen]

It's totally normal for there to be metallic sludge in the oil - like sand.

It's not normal for there to be shavings like sawdust or BBs

This is where I wish I'd seen a picture of it... maybe they still can.

 

[Ducati1098]

Oof that's what I was worried about. I guess my question is really, do you think it's safe to keep daily driving for that many months? The advisor talked about it as if it could fail at any time, but then again he's not the actual mechanic doing the dirty work. I wish I'd asked for a picture when they first told me about it.

Nice Ducati by the way

Thanks.
Hard to say whether it's safe or not without being able to see it. I would probably still ask them for a picture.
I'd be willing to bet it's probably a normal amount of build up if you didn't ever notice a noise or anything.

 

[PWillette]

I guess they need to confirm what was found...big chunks or just flakes? It's been pretty well documented that these diffs generate a lot of metal flakes. IMO Have them change the fluid and go on your trip. FWIW this will still be covered under your powertrain warranty.

 

[Ducati1098]

FWIW this will still be covered under your powertrain warranty.

This is a very good point.
@jdoxen You still have a while before you're out of coverage

 

[indio22]

As long as they're ok with you driving out of state, I'd put the trip miles on the Mustang and be off to the races. I'm from Chicagoland, how bad could the weather be on the coast.

 

[projectbadlands]

Ask for a picture and post it so we can actually judge these metal shavings

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