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Dealership found metal chunks in rear end just before Oregon trip

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jdoxen

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He was in fact able to get me a picture and well, I think we can all agree this is more than normal wear. He said this is "one of" the chips they found. Can't tell *what* it is from this angle and at this resolution but... definitely more than the expected amount of glittery powder.
Ford Bronco Dealership found metal chunks in rear end just before Oregon trip image6989[1]
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Ducati1098

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He was in fact able to get me a picture and well, I think we can all agree this is more than normal wear. He said this is "one of" the chips they found. Can't tell *what* it is from this angle and at this resolution but... definitely more than the expected amount of glittery powder.
image6989[1].jpg
Oof. Yeah that's not ideal lol
 

projectbadlands

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He was in fact able to get me a picture and well, I think we can all agree this is more than normal wear. He said this is "one of" the chips they found. Can't tell *what* it is from this angle and at this resolution but... definitely more than the expected amount of glittery powder.
image6989[1].jpg

Wow! That's a chunk! Did they remove the cover and take a look at the ring gear or any possible component that chunk came from?

Im curious, what prompted them to drain the fluid anyway?
 

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Wow! That's a chunk! Did they remove the cover and take a look at the ring gear or any possible component that chunk came from?

Im curious, what prompted them to drain the fluid anyway?
I can ask if they've removed the cover yet but my guess is they're not planning to do any more work on it until the replacements come in. I did ask and he said they have looked at the gears (didn't send me a picture though) and that's why they want to do the warranty repair. I think my advisor is starting to get a little sick of me...

They drained the fluid just because it's driven its first 30,000 miles, for better or worse I took them at their word that it should be done.
 
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Yikes! That's a chunk. Ignore my previous post. Good luck.
 

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Did they actually wipe that booger off the drain plug onto a rag to verify that it's really a chunk? Sometimes the tiny little bits sort of pile up on the magnet and look like a chunk when they're not. I've had a sphincter tightening moment or two over the years with this.

Pulling the cover will tell quickly if there's a tooth missing or there's abnormal wear. Beyond that it might even be a chunk left behind from casting and machining.
 

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Not sure what that is but it's not supposed to be in there. I assume whomever was doing the oil changes checked the fluid level at each service and it wasn't there last time. If this was recent, there's a problem and I wouldn't trust it without a complete teardown and inspection.
 
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Got an update from my service advisor: the rear end assembly should come in tomorrow, which is great news! However he said it's a big job and might not be done until Monday or Tuesday... by which time I will already be out of state. They said I can keep the loaner for that time, still it's a little unfortunate the timing will just barely not work out. I guess I should just be thankful it was fixed in 2 weeks and not the several months some of you mentioned...

As far as the actual damage, the way he described it they opened up the diff case and found more chunks similar in size to that one. Definitely not an overreaction to replace the whole thing.
 

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If it were me, I’d leave it and let the dealer take care of business. They seem to be taking care of this with no issue…big plus.

I’d ask them for a AWD or 4x4 for the trip, if no go. Maybe just rent a vehicle for your trip and call it good.

Just having a dealer take care of things without a fight is gold in my book.
 

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Coming from two previous 4Runners, I decided this was the right car to opt for the extended warrantee. I have a Wildtrak and my son has a Bronco Sport Badlands - I can't keep track of how many recall notices I've had so far. Currently on the list for intake valves, Bilstein shocks, corroding battery straps, all with no current solutions.

And suspiciously, within less than 24 hours of my 3-year warrantee expiring, I got new error messages for blind spot monitoring, and rear collision assist failures.
 

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I agree with @bassist, I actually kind of miss my old rear wheel drive Mustang when driving in snow. It wasn’t great in deep snow where the undercarriage would drag, but I like rear wheel drive better in light snow or ice. Unless you plan on going back woods with it, I think you’ll be fine.
 

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Got an update from my service advisor: the rear end assembly should come in tomorrow, which is great news! However he said it's a big job and might not be done until Monday or Tuesday... by which time I will already be out of state. They said I can keep the loaner for that time, still it's a little unfortunate the timing will just barely not work out. I guess I should just be thankful it was fixed in 2 weeks and not the several months some of you mentioned...

As far as the actual damage, the way he described it they opened up the diff case and found more chunks similar in size to that one. Definitely not an overreaction to replace the whole thing.
Wonder how they got one so fast. There are others on here waiting for the same thing since like last November at least.
Either way, glad to hear they have it figured out.
 

SunilD

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Get some chains for the Mustang, and you'll be fine. I used to drive my GT over highway 80 all the time :). Maybe you can get Ford to reimburse you haha

Places like O'Reilly auto parts will let you return the chains if you don't actually use them.
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