Front Differential Failure Club

[Brian_B]

It is a non sas with the advanced transfer case so I'm assuming m190 W/O FAD. Rear ratio is 4.27 according to the 2L axle code in the door.

That's very helpful. Thanks.

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[Beach_Bum]

Live in VA but travel to St. Augustine multiple times a year. Beach is St. Augustine, trails are Ocala National Forest, great place to explore.

I figured such on both the inland trails and the beach. Live in the Ancient City for 20 years.

 

[Stanley Crewell]

I figured such on both the inland trails and the beach. Live in the Ancient City for 20 years.

We've actually had a condo in St Augustine for about 14 years and eventually the city will be our permanent home. Love the area .

 

[Dz117]

Wow! I was worried I was the only one!

I have a 2dr Black Diamond 2023 (non-SAS) with the m190. Purchased October 2023 and have 52k miles. I have done extensive cross country trips loaded up, tons of local Uhaul trailer moves, overlanding and moderate off roading/ rock crawling.

I’ve spent 3 months trying to diagnose, was told it was my tires, then wheel bearing and then finally we were able to to diagnose it as a driver side part of the differential.

I was getting pulsing humming noises at between 60-70 mph precisely from that location.

I had to take it to the dealer twice before they were able to replicate (also shoutout to Johnson Brother Ford Dealership in Temple, TX for their help). I was prepared to pay out of pocket to just switch the differential as I’m about to do a 2500 mile cross country move pulling a Uhaul. Long story short they were able to replicate and are replacing under warranty.

Ford warranty process is pretty frustrating; I wish Ford had a specific 4x4 maintenance division where the techs are more conservative; I rather throw parts at the problem than wait for something to catastrophically fail 300 miles from the nearest gas station much less dealership. I think the biggest issue is the service support we have is focused to cater to commuter vehicles that rarely leave a 25mile radius much less sustained severe duty use.

 

[23OBX2.7]

The service rep didn't have any real explanation just said that she's seen a few lately and believes there will be a TSB coming out at some point to address them. No idea what a TSB would say other than to check the fluid level every time you bring it in for an oil change. I will probably have them change the rear diff fluid when I take it back for the repair just because that's the only one that will not have been changed at this point.

Maybe another short fill like 10R80 on S550 mustangs that persisted for years...

 

[2023bronco]

Are these failures because of the common failure of the pinion seal?

 

[Frankie945]

Must be a front diff bug going around because we had a member in our Facebook group recently post this. I’ll quote him.

“My wife and I had a very scary experience today. I believe the front diff locked up and broke on us. We were like 1/4 mile from our house going about 45mph on a straight and it was like I slammed on the brakes although I didn't. The font tires locked up, screeched then a loud bang! I got to my street stopped, put it in 4x4 and it wont go forward. has anyone else experienced this? I'm glad I wasn't on curvy back roads or the highway. I know it will probably be fixed under warranty I'm just seeing if anyone else has experience this?”

 

[RedBeard-421]

Are these failures because of the common failure of the pinion seal?

I’m not a mechanic by any means. But if I had to guess, I believe it definitely starts with the pinion seal. Once you notice it’s losing fluid. It’s already starting to create metal chips rolling around, from lack of fluid. Once the pinion seal is replaced. Damage is already done. Only a matter of time. I believe my seal was leaking again. Either way, mine was making a rumble sound as indicated. Warranty is replacing mine as we speak.

 

[AK007]

Ive had issues with leaking seal by the front dif and the first dealer tried use a liquid seal. Took it to another dealer and they replaced the front axle pinion seal which is a know issue on Bronco's and there is a TSB. I smelled something everytime I used 4A and told the dealer multiple times but they didnt do anything or didnt find any solutions until recently and I'm at 20k miles on a 2023 4dr Bronco WT. I do have the 10 year Premium Extended Warranty and concerned about long term damage. My 3 year 36k bumper to bumper expires tomorrow.

 

[Rob_Broncowski]

Must be a front diff bug going around because we had a member in our Facebook group recently post this. I’ll quote him.

“My wife and I had a very scary experience today. I believe the front diff locked up and broke on us. We were like 1/4 mile from our house going about 45mph on a straight and it was like I slammed on the brakes although I didn't. The font tires locked up, screeched then a loud bang! I got to my street stopped, put it in 4x4 and it wont go forward. has anyone else experienced this? I'm glad I wasn't on curvy back roads or the highway. I know it will probably be fixed under warranty I'm just seeing if anyone else has experience this?”

This sounds similar to something that happened to me last year. I took my family up to NH for a weekend in the mountains. After spending a couple of hours on the highway (sport mode, 4A) I exited on to the surface streets. As I was coasting up to a red light it started to stumble and I said to my wife, it feels like it's going to stall. I was approaching a gas station so I planned to pull in and take a look. Before I could even make the turn it died and chirped the tires while coming to a sudden stop. I thought maybe the fuel pump went out but I don't think that would explain the failure mode. It felt like someone threw it into park. To my surprise, it fired back up and it has run completely fine for the past ~6 months. I guess I'm going to have to crawl under it and take a closer look at the seals now. I'm glad we are starting to track issues like this on here in case this snowballs into something like the early 2.7 engine failures.

 

[Beach_Bum]

Must be a front diff bug going around because we had a member in our Facebook group recently post this. I’ll quote him.

“My wife and I had a very scary experience today. I believe the front diff locked up and broke on us. We were like 1/4 mile from our house going about 45mph on a straight and it was like I slammed on the brakes although I didn't. The font tires locked up, screeched then a loud bang! I got to my street stopped, put it in 4x4 and it wont go forward. has anyone else experienced this? I'm glad I wasn't on curvy back roads or the highway. I know it will probably be fixed under warranty I'm just seeing if anyone else has experience this?”

Sounds exactly like when Miss Ashley (@618TRVLWILD ) had her front diff grenade. It was surmised that her front pinion seal was leaking about a month before. Here are a few pictures of the metal salad.

 

[huey]

Sounds exactly like when Miss Ashley (@618TRVLWILD ) had her front diff grenade. It was surmised that her front pinion seal was leaking about a month before. Here are a few pictures of the metal salad.

schnikeys!!!
thx for posting those pics - those gears look like they are made of butter

 

[Beach_Bum]

schnikeys!!!
thx for posting those pics - those gears look like they are made of butter

This was back when Ford didn't know what was going on. Those pictures at the time were asked by Ford not to be shared publicly. Her Bronco was a MY'21 Sasquatch Big Bend 2-dr. Her front diff yeeted itself in Dec. 2022. Just driving straight on back road when it ate the metal salad and grenaded.

 

[Oldhippie]

Seldom is the pinion seal the actual problem if it is leaking….usually the pinion shaft is loose (bad bearing and/or adjustment) and moving around taking out the seal and gears…

 

[huey]

This was back when Ford didn't know what was going on. Those pictures at the time were asked by Ford not to be shared publicly. Her Bronco was a MY'21 Sasquatch Big Bend 2-dr. Her front diff yeeted itself in Dec. 2022. Just driving straight on back road when it ate the metal salad and grenaded.

someone on here once said save posts....just in case the info gets deleted

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