Front Differential Failure Club

[Valhalla]

I think this issue is gone after 2023.

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[LRNAD90]

I think this issue is gone after 2023.

I'd like to believe that, but based on what information? This Poster's details say 2024, and he is reporting a failure at 20K miles...

 

[Atthelake152]

Add me to the list. 21 FE with 37k miles.

 

[BroncoAdventure]

From what I'm reading, it's happening to both 4a and non 4a differentials? The one 24MY BD non sas, would be a non 4a truck if im not mistaken...

 

[Valhalla]

It is the differential; it does not matter the drive.

 

[dgorsett]

It is the differential; it does not matter the drive.

Kinda, a 4a would not have FAD, most but not all Part time would have FAD

 

[Valhalla]

Kinda, a 4a would not have FAD, most but not all Part time would have FAD

I'd have to see where that is, when you order an axle, it is not differentiated for 4A or standard. So, you believe that the fact that the transfer case can decide to turn the front axle instead of the hubs just turning the axles is causing this? Or am I missing something?

 

[dgorsett]

I'd have to see where that is, when you order an axle, it is not differentiated for 4A or standard. So, you believe that the fact that the transfer case can decide to turn the front axle instead of the hubs just turning the axles is causing this? Or am I missing something?

I really have no idea what causes failure. Just providing a data point. If all diffs that fail have or don't have FAD that would be a clue as to a cause

 

[dgorsett]

A quick look back through the thread indicates it happens to both m190 and M210 diffs all but one where non FAD with 4a, but one FAD and part time. So no real commonality..?

 

[Valhalla]

I believe it is a supplier issue from Eaton.

 

[RedBeard-421]

I was never told what actually caused the issue. From what I gather, my first issue was the leaking pinion seal. Once that was fireplaced. Few months later starts leaking again, and rumbling noises from driver side. Cv axle wasn’t replaced correctly. Had metal shavings in the fluid. So that’s how my FDU got replaced. Thanks warranty

 

[Brian_B]

I'd have to see where that is, when you order an axle, it is not differentiated for 4A or standard. So, you believe that the fact that the transfer case can decide to turn the front axle instead of the hubs just turning the axles is causing this? Or am I missing something?

The smaller m190 FDU is different for 4A vs part time

 

[DGE1993]

Just wanted to add myself to the list. I think I have the record for fastest failure as well. I ordered a 4.70 M210 from the Ford Performance website. Installed it and filled with fluid. Made it three miles before I came to a hard stop from 30mph. Axle was siezed solid. Luckily I was on a gravel road with no one around. Couldn't imagine having that happen at highway speeds....

My old axle (M190 with FAD) was still going strong at 31k. Thought I was replacing it with the "stronger" axle.... Now I have my concerns....

 

[glonco]

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?”

My brother was driving my Badlands on the highway in a town about 800 miles from home when the front differential suddenly failed. It seized completely, which caused the front driveshaft to snap off. The broken shaft swung around, smashed the transmission oil pan, and kinked the oil lines—luckily, the lines didn't leak. He had the truck towed to the nearest mechanic, replaced the oil pan, and then drove it back home without the front driveshaft installed.

I still don’t know what caused the failure, but the transfer case motor also failed at the same time.

I’ve since installed a new front driveshaft and a new transfer case motor, but the front differential now clicks when driving forward in 2H, and it makes a loud knock in reverse that causes the truck to jerk.

To make things worse, the electronic sway bar disconnect has also failed out of warranty, and now the front differential appears to be gone as well.

 

[Bronco Toad]

Out of curiosity did anyone have a leak prior to?

Took my 22 Badlands non sas in for a recall they noticed a leak investigated it and found the pinion seal leaking.

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