2022 Ford Bronco rear differential noise due to bearing failure

[cameronrbiffle]

I'm posting this for if anyone else who may be having the same issue, when I first noticed the noise, I searched the internet for answers found nothing. One evening my wife was pulling into the driveway and I was standing in the front yard. I hear what sounded like metal rubbing together almost like a brake caliper stuck and the rear brake rotor/brake pad rubbing each other. I drove the bronco down the road with all the windows down to verify the noise is coming from the rear. The noise started when I would get to around 20 MPH and progressively was louder the faster, I went. Drove the Bronco in the barn and lifted it up then removed both rear wheels and brakes. I had my wife get in and take to 20mph with the wheels off of the ground it was obvious to tell its coming from the rear differential. I was thinking axle bearings but they looked fine. Drained oil from the diff and found lots of metallic glitter. Called the stealership for warranty, but I already had too many miles at 79,000. I thought drivetrain was 100k but apparently, I was wrong on that its 5 year 60k miles. After stealership enormous guestimate quote to change out the Diff I decided to rebuild the one I have myself in my shop after multiple shim changes and a few extra special tools total cost was roughly $850 ordered from yukon gear. I do not think you should have rear differential bearing failure at 79k, I believe it was a metal issue with the bearing material or a not changing the oil soon enough after break in issue. Knowing what I know now I would not wait to change the differentials gear oil at 150k like ford recommends I would change it a lot sooner, ordering oil online after rebuild for front and rear oils was around $50 bucks using Lucas synthetic gear oil. I hope this helps someone see the pictures attached. Failure was found in 4 bearings both pinion bearings and both carrier bearings. Axle bearings were fine but I replaced them and the seals just because I was already there and they were in contact with the same oil with the metal contamination as the ones that failed. It can be a little intimidating at first but if you take your time and read yukons instructions it's not too bad.

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[VGK_Fan]

I had what sounded like wheel bearing noise coming from the back of my '21 when I drove it off the lot. It was pronounced when I came off the accelerator. Took it in for first oil chance and had them check it out. Turns out there was significant damage in the rear diff that was replaced under warranty. No pictures but there were "several missing teeth", per the service adviser. Sorry to hear you're having the same issue and it's out of warranty. I agree the powertrain warranty should be longer than 5/60K

 

[ILoveToDrive]

2023 Badlands Sasquatch...33k miles. Started hearing a variety of noises....some from friction, other possibly turbo related. Took it to the dealer who just informed me of a catastrophic failure of the differential. Waiting to hear the detailed diagnosis. Not even discussing the other noises yet. I love the truck, but the quality issues on this vehicle are absurd bordering on criminal.

 

[oneryan]

i'm currently having a rear diff installed on my 24 Heritage with 25k on it.

seems to be a thing..

 

[Glenjafett]

23 Badlands, 35k. At the dealership now for a failed rear diff. No firm diagnosis yet.

 

[Alanp970]

Which engines y’all running? I wonder if failures are higher on V6’s with all that extra torque?

 

[oneryan]

Which engines y’all running? I wonder if failures are higher on V6’s with all that extra torque?

2.3 here. just luck i guess

 

[Alanp970]

2.3 here. just luck i guess

Well that blows my theory

 

[Glenjafett]

Well that blows my theory

2.7 for me.

 

[ILoveToDrive]

2023 Badlands Sasquatch...33k miles. Started hearing a variety of noises....some from friction, other possibly turbo related. Took it to the dealer who just informed me of a catastrophic failure of the differential. Waiting to hear the detailed diagnosis. Not even discussing the other noises yet. I love the truck, but the quality issues on this vehicle are absurd bordering on criminal.

They now informed me that Ford would not authorize replacement of the casing, but when they started pulling it apart, a bunch of metal came out. Now Ford has authorized replacement of the casing as well.
I’m still waiting on the diagnosis of the flutter sound which they attributed to a waste gate related issue.

 

[ILoveToDrive]

Which engines y’all running? I wonder if failures are higher on V6’s with all that extra torque?

2.3L

 

[Glenjafett]

After 2 months at the 2nd dealership, they have diagnosed it as a bad rear pinion. Said it had significant pitting etc. My dealership claimed they had to order "special tools" to swap bearings etc. Every 3rd day it was a new part being ordered. Super frustrating. They did not replace the casing. They are now "tempering" the new bearings stating there is a specific break in period that requires 20 minutes of running then cooling three times... I should have it back at the end of the week. I'm hopeful... but not super optimistic.

23 Badlands, 35k. At the dealership now for a failed rear diff. No firm diagnosis yet.

 

[oneryan]

i asked my dealer if there was any specific break-in procedure i should follow and they just said drive it!

it's been a few thousand miles.. so far so good

 

[khill007]

23 2 door Wildtrak

In shop now, covered under drivetrain warranty thank goodness.

I had same issue, 50k miles. Metal in differential fluid.

Symptoms were metallic grinding on load starting at around 20 mph. Off throttle no noise until costing to stop. I was afraid it was not going to be covered but Ford approved. I have seen a few threads where this has happened. Not sure if there is a TSB or not.

Thought I would contribute.

 

[khill007]

23 2 door Wildtrak

In shop now, covered under drivetrain warranty thank goodness.

I had same issue, 50k miles. Metal in differential fluid.

Symptoms were metallic grinding on load starting at around 20 mph. Off throttle no noise until costing to stop. I was afraid it was not going to be covered but Ford approved. I have seen a few threads where this has happened. Not sure if there is a TSB or not.

Thought I would contribute.

Thought this might help. Looks like same issue as OP????

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