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Front Differential Failure Club

Boostedblues

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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 me. Thanks for posting Frankie. The dealer called me saying it needs a whole new FDU and a front drive shaft. My wife drove it up to the dealer Monday, which is about 4 miles away and no speed limits that exceed 35mph. she said it was making a wearing noise like a bearing failing. and that it binded up a couple times and it was obviously in 2wd. Dealer said it will hopefully finished middle of next week.
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userdude

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My front diff went out on my BL Sas and the dealer replaced the whole axle under warranty. What the notes said is it was missing one of the mounting bolts. So don't know if this matches up with what you're talking about. It also hadn't failed, it was just whining and grinding like an oversexed Rottweiler.
 

userdude

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This thread is going to give me nightmares.
You mean the one where you're being chased by a bloody knife wielding clown whose running on the walls and ceiling of a broken down house of mirrors while Bessie Smith's "Baby Won't You Please Come Home" plays too slow and there's a whole pet cemetery in the corner of the living room painted with the most yellow paint that--

Oh, you mean about the diffs. My bad.

:whistle: 🏃‍♂️ 🗡 👋 🤡
 

BR549

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What were typical symptoms folks have seen prior to failure/replacement?

I have had an intermittent "rumble" for a few weeks that I have never experienced before in any other vehicle. Best description is that of running over a rumble strip that is so light you can barely hear or feel it, but it is there. And it is periodic, about 3-4 seconds "on" and 4-5 seconds "off". Normally between 45 and 60 mph, both loaded and not loaded. Some days it is there, some days not, some days it is there for 10 miles or so and then goes away. Seems to come from front/mid of vehicle.

CV or diff or ????

'23 2DR, non-sas, 7MT, ~38k miles
 

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Archedamian

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My front diff went out on my BL Sas and the dealer replaced the whole axle under warranty. What the notes said is it was missing one of the mounting bolts. So don't know if this matches up with what you're talking about. It also hadn't failed, it was just whining and grinding like an oversexed Rottweiler.
I also have a 2022 2 door Badlands that was leaking fluid on the front driver’s side and had my whole axle replaced under warranty. 34,000 miles.
 
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Stanley Crewell

Stanley Crewell

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What were typical symptoms folks have seen prior to failure/replacement?

I have had an intermittent "rumble" for a few weeks that I have never experienced before in any other vehicle. Best description is that of running over a rumble strip that is so light you can barely hear or feel it, but it is there. And it is periodic, about 3-4 seconds "on" and 4-5 seconds "off". Normally between 45 and 60 mph, both loaded and not loaded. Some days it is there, some days not, some days it is there for 10 miles or so and then goes away. Seems to come from front/mid of vehicle.

CV or diff or ????

'23 2DR, non-sas, 7MT, ~38k miles
Mine sounded almost like a rock in the tire but with a slightly softer sound that you could only hear from inside the vehicle with the radio off. Put the window down and try and hear it and you couldn't. Mechanic even had a hard time identifying where it was coming from. Actually drove with that noise for 2000 miles thinking it was a tire noise. Got new tires and realized it wasn't. 😬
Just glad it didn't go boom! Although the whole time it never got worse.
 

Beach_Bum

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someone on here once said save posts....just in case the info gets deleted :wink::wink::wink:
Those pictures are safe. Enough water has flowed under the bridge that it no longer is a secret. She shouldn't have gotten those as they were photos taken by the tech to send to Ford. But that tech also is her personal mechanic for mundane service when he's off the clock. At the time, Ford wanted to keep it quiet.
 

RedBeard-421

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Update, w
What were typical symptoms folks have seen prior to failure/replacement?

I have had an intermittent "rumble" for a few weeks that I have never experienced before in any other vehicle. Best description is that of running over a rumble strip that is so light you can barely hear or feel it, but it is there. And it is periodic, about 3-4 seconds "on" and 4-5 seconds "off". Normally between 45 and 60 mph, both loaded and not loaded. Some days it is there, some days not, some days it is there for 10 miles or so and then goes away. Seems to come from front/mid of vehicle.

CV or diff or ????

'23 2DR, non-sas, 7MT, ~38k miles
sounds like the diff issue I have. Better take it in soon. Especially still under warranty.
 

618TRVLWILD

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Here’s few more pics from mine showing the crack in the casting! It was def an interesting day to say the least. I was traveling about 70 when I skid to a stop.
Had to be towed to the dealer. They had it about two weeks. It had 10k miles. I did end up with whole new front axle, then they went ahead replaced the drive shaft!
I still to this day think some diffs are being under filled with fluid when assembled.

Ford Bronco Front Differential Failure Club 17A23BCA-31F2-4927-8F14-E531F6552EE0


Ford Bronco Front Differential Failure Club 9C7724D3-A3B0-4F49-B370-EA3CE4C16DFE


Ford Bronco Front Differential Failure Club 27B3F9DB-64B1-4C61-922D-4E4337D1AF7B
 
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23OBX2.7

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Here’s few more pics from mine showing the crack in the casting! It was def an interesting day to say the least. I was traveling about 70 when I skid to a stop.
Had to be towed to the dealer. They had it about two weeks. It had 10k miles. I did end up with whole new front axle, then they went ahead replaced the drive shaft!
I still to this day think some diffs are being under filled with fluid when assembled.

17A23BCA-31F2-4927-8F14-E531F6552EE0.webp


9C7724D3-A3B0-4F49-B370-EA3CE4C16DFE.webp


27B3F9DB-64B1-4C61-922D-4E4337D1AF7B.webp
Major safety issue you should report to NHTSA thats completely ridiculous.
 

618TRVLWILD

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Major safety issue you should report to NHTSA thats completely ridiculous.
Say why Ford wanted it hush hush. At the time it happened. Think I was one of the first few people that I even knew it happened too, then few more trickled in. One guy happened to was on the interstate. Mine was in 2022! I would have thought by now it be an issue of the past!
Tyler in Texas was the one I mentioned on the interstate. The one makes the portals. I can’t remember their 4x4 shop handle.

***bronc buster!
 

Valhalla

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My M210 of my 23 squatch bad failed on the trail first 2 months of ownership, second failed weeks after installation, that was almost 3 years ago.
 

Boostedblues

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What were typical symptoms folks have seen prior to failure/replacement?

I have had an intermittent "rumble" for a few weeks that I have never experienced before in any other vehicle. Best description is that of running over a rumble strip that is so light you can barely hear or feel it, but it is there. And it is periodic, about 3-4 seconds "on" and 4-5 seconds "off". Normally between 45 and 60 mph, both loaded and not loaded. Some days it is there, some days not, some days it is there for 10 miles or so and then goes away. Seems to come from front/mid of vehicle.

CV or diff or ????

'23 2DR, non-sas, 7MT, ~38k miles
Mine gave no warning. The front tires just locked up outta no where.
 

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Say why Ford wanted it hush hush. At the time it happened. Think I was one of the first few people that I even knew it happened too, then few more trickled in. One guy happened to was on the interstate. Mine was in 2022! I would have thought by now it be an issue of the past!
Tyler in Texas was the one I mentioned on the interstate. The one makes the portals. I can’t remember their 4x4 shop handle.

***bronc buster!
This defect under the rug sweeeping is exactly why Ford was fined a zabillion dollars and remains under third party defects audit oversight causing recalls and TSBs to attain the highest innthe world next to Tesla.
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