Front Differential Failure Club

[618TRVLWILD]

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.

Yikes! My bronco has three current recalls at the moment. Plus I got a few other things going on too! Gotta love it. I hope one day they slow down and get it together!

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[userdude]

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.

Mine was around 34k too.

 

[White Zombie]

here's a question for those that have had this front diff issue. Are you running in the 4A in the transfer case? just something that is interesting. Of course, I realize that there are no locking hubs and the front axle is also always spinning, sort of like the old school full time 4X4, even when its in 2wd. I'm old school 4X4 and would much rather have a locking hub. LOL Just for that very reason and its probably helping the cause of the diffs failing.

 

[Valhalla]

here's a question for those that have had this front diff issue. Are you running in the 4A in the transfer case? just something that is interesting. Of course, I realize that there are no locking hubs and the front axle is also always spinning, sort of like the old school full time 4X4, even when its in 2wd. I'm old school 4X4 and would much rather have a locking hub. LOL Just for that very reason and its probably helping the cause of the diffs failing.

I only run 4A if it is wet. So no, I am not routinely using it. At the time of failure, it had been offroad twice (failed the second time) and in 4A once, the second one failed on the way home from the dealer in 2H.

 

[White Zombie]

HMMM well it was a thought. LOL
I still would rather be able to run in "free wheel" with lock out hubs but not so much with these axles.

I only run 4A if it is wet. So no, I am not routinely using it. At the time of failure, it had been offroad twice (failed the second time) and in 4A once, the second one failed on the way home from the dealer in 2H.

 

[Boostedblues]

here's a question for those that have had this front diff issue. Are you running in the 4A in the transfer case? just something that is interesting. Of course, I realize that there are no locking hubs and the front axle is also always spinning, sort of like the old school full time 4X4, even when its in 2wd. I'm old school 4X4 and would much rather have a locking hub. LOL Just for that very reason and its probably helping the cause of the diffs failing.

I was in 2wd. i had it in 4x4 a few days earlier to get through snow and ice that was completely covering the road.

 

[IndyGuyBeast]

Mine failed catastrophically a couple weeks ago., right around 20,000 miles. I heard/felt a thud sound under the vehicle, then the rumble/grind sound whenever the wheels were turning. I don't know if it would have made it to the dealer under its own power, and I wasn't going to chance it. I had it towed, and they replaced the front differential under warranty. I'm very glad the front wheels didn't lock up.
I had used 4H a few times during recent snow storms, and also on my property. I did pull one of my 2WD vehicles out that had been parked before the snow hit, but this was hardly a power-lift.


Don't these Broncos have a 60,000 mile powertrain warranty? I would say the front differential is part of the powertrain.

 

[White Zombie]

I think it miles or years but I could be wrong

Mine failed catastrophically a couple weeks ago., right around 20,000 miles. I heard/felt a thud sound under the vehicle, then the rumble/grind sound whenever the wheels were turning. I don't know if it would have made it to the dealer under its own power, and I wasn't going to chance it. I had it towed, and they replaced the front differential under warranty. I'm very glad the front wheels didn't lock up.
I had used 4H a few times during recent snow storms, and also on my property. I did pull one of my 2WD vehicles out that had been parked before the snow hit, but this was hardly a power-lift.


Don't these Broncos have a 60,000 mile powertrain warranty? I would say the front differential is part of the powertrain.

 

[Stanley Crewell]

here's a question for those that have had this front diff issue. Are you running in the 4A in the transfer case? just something that is interesting. Of course, I realize that there are no locking hubs and the front axle is also always spinning, sort of like the old school full time 4X4, even when its in 2wd. I'm old school 4X4 and would much rather have a locking hub. LOL Just for that very reason and its probably helping the cause of the diffs failing.

I normally run 2H and use 4A when it's wet or in light snow. 4H for deep snow. Probably have at least a thousand miles in sand and Forest roads. 75% in a sand. 4H for most of that. Never really have a reason for 4L. Worked perfectly for 58,500 miles.

 

[RedBeard-421]

Are y’all having an alignment done after FDU replacement?

 

[White Zombie]

Did your front differential go out also? Just wondering, I don't recall from previous post.

I normally run 2H and use 4A when it's wet or in light snow. 4H for deep snow. Probably have at least a thousand miles in sand and Forest roads. 75% in a sand. 4H for most of that. Never really have a reason for 4L. Worked perfectly for 58,500 miles.

 

[Stanley Crewell]

Dude your front differential go out also? Just wondering, I don't recall from previous post.

No. From everything I've read mine seems to be an extremely mild issue in comparison to those that have had it simply explode. I was just having a very light bumping sound that I knew was coming from the driveline but wasn't sure where. The dealer diagnosed the problem and said it needed a new front differential. Told me it would be 3 days before they could get one and I can either leave it or take it home and bring it back which meant they weren't worried about anything catastrophic. Like I said in my original post I originally thought it was a tire issue till I got new tires and the noise remained. That noise was there for at least 2,000 miles so I'm really surprised they have to replace the whole front differential and it's not something less involved.

 

[Brian_B]

Are y’all having an alignment done after FDU replacement?

Depends on how they drop the front axles out. If you go via the LCA you have to pull the alignment cams and that will require a new alignment to make sure you got it back in right (unless you have cam locks and mark 'em). If you go via the UCA and don't monkey with the tie rod adjustment, you should be right back where you started.

The FDU and axles themselves shouldn't affect the alignment. It's just in how you get them in and out for the FDU replacement.

 

[dgorsett]

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…

THIS, I would agree. And for the leak to be the cause A LOT of lube would have shown up on the garage floor first, not just a seep around the seal.

Now that said, on my second or third oil change I decided to check my lube levels, front, rear and transfer case were each about 8 oz low, no leaks, factory fill, that's not good,

 

[Quest]

I've gone through two FDs. First was around 20k, and the second was the day after they fixed the first. Dealership assumed I was beating the hell out of it and warned it was unlikely to get covered again. The fact is, I barely did anything both times, and everyone with me has been shocked it blew with what was being done at the time they failed.

The first time I was on a muddy hill in the woods. Tires caked in mud (still had stock ATs). I attempted to turn around and got a rock behind the driver's front tire. Put out recovery boards on all four tires. I did not smash the gas, just giving it gas, trying to rock it out. Boom, FD breaks. The second time, I ended up high-centered on a dirt/rock berm. Tried to rock it out as two tires still touched, boom FD breaks. Neither time was there a lot of torque with sudden traction. Just slipping in mud. Indication was that the spline gear snapped. 4L both times with rear-dif locked.

23 BD 4DR V6 non-sas.

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