Front Differential Failure Club

[Stanley Crewell]

Today I joined what is apparently a long line of owners with front diff issues. Have been hearing a slight thumping sound for a while but though it was the unusual tread wear on the tires since it started shortly after the last rotation. However, after replacing the tires recently the noise remained. Dropped it off at the dealer today and got a call saying the front diff needs to be replaced. Service rep said there were 3 other Broncos there for the same thing. Good news is that it didn't fail on the road or deep in some wilderness area. Also, the rep said a replacement will be here in 3 days. When she said front diff failure I was dreading hearing, "backordered with no anticipated delivery date" phrase. Guess we'll see if it actually shows in 3 days. Anyway, was just wondering how many others have had similar issues and what if any issues turned up after the diff was replaced. Can't complain too much since this is the first issue I have had in almost 60k. This thing has been so much fun.

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[RedBeard-421]

Today I joined what is apparently a long line of owners with front diff issues. Have been hearing a slight thumping sound for a while but though it was the unusual tread wear on the tires since it started shortly after the last rotation. However, after replacing the tires recently the noise remained. Dropped it off at the dealer today and got a call saying the front diff needs to be replaced. Service rep said there were 3 other Broncos there for the same thing. Good news is that it didn't fail on the road or deep in some wilderness area. Also, the rep said a replacement will be here in 3 days. When she said front diff failure I was dreading hearing, "backordered with no anticipated delivery date" phrase. Guess we'll see if it actually shows in 3 days. Anyway, was just wondering how many others have had similar issues and what if any issues turned up after the diff was replaced. Can't complain too much since this is the first issue I have had in almost 60k. This thing has been so much fun.

Dropped mine off recently. Same issue, I thought it was a wheel
Bearing. Took it in for a warranty claim, and they called back and said it was my FDU. Complete replacement courtesy of warranty! Unfortunate, but it is what it is. 42k miles. And we do take ours off road from time to time.

 

[White Zombie]

interesting. Guess I have something to look forward to with my 22 2dr that only has 15k on it at the moment

 

[Stanley Crewell]

Dropped mine off recently. Same issue, I thought it was a wheel
Bearing. Took it in for a warranty claim, and they called back and said it was my FDU. Complete replacement courtesy of warranty! Unfortunate, but it is what it is. 42k miles. And we do take ours off road from time to time.

We do a fair amount of off-roading but it's mostly sand and Forest roads. No interest in rock crawling.

 

[Bronco Toad]

I dig the lights!!!

 

[Beach_Bum]

We do a fair amount of off-roading but it's mostly sand and Forest roads. No interest in rock crawling.

Your location indicates VA. But those photos look like Florida especially the beach passes on your windshield.

 

[Stanley Crewell]

Your location indicates VA. But those photos look like Florida especially the beach passes on your windshield.

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.

 

[Brian_B]

Any word on exactly what is failing on the FDU? Is it an internal bearing or something?

 

[Stanley Crewell]

I dig the lights!!!

Had a full size 86 Bronco with the same lights. Got them for a little nostalgia.

 

[Stanley Crewell]

Any word on exactly what is failing on the FDU? Is it an internal bearing or something?

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.

 

[TacosTuesday]

what year is your bronco?

 

[Stanley Crewell]

what year is your bronco?

2023. 58,580 miles. Got in just under the powertrain warranty although I do have an extended one.

 

[TacosTuesday]

dang, was hoping it wasn't also a '23 like mine... something to look forward to i guess

 

[Brian_B]

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.

I should also verify - non-SAS without the front locker (m190) or front locker (m210) front end, and/or know your gear ratio?

Outer banks could have any of the 3 FDUs (m190 w/o FAD, m190 w/ FAD, or m210). I don't think there have been any changes with the FDUs internally across the model years - there was an update to the hanger to address cracking at some point though.

 

[Stanley Crewell]

I should also verify - non-SAS without the front locker (m190) or front locker (m210) front end, and/or know your gear ratio?

Outer banks could have any of the 3 FDUs (m190 w/o FAD, m190 w/ FAD, or m210). I don't think there have been any changes with the FDUs internally across the model years - there was an update to the hanger to address cracking at some point though.

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.

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