Front diff failed at 20K, then again at 40K. I started hearing noise at 60K, but the dealer told me I was crazy. They said they drained the fluid and refilled after "it looked fine."

With the noise still there, I went to another dealer and they immediately heard the issue. They replaced the IWE, which didn't solve the problem.

After some additional diagnosis, they identified a failed front diff, and have also found issues with the front axel.

Anyone else with similar experiences? Given that we are now on attempt 5 to fix the concern (which originally started well within warranty), is there any chance a buyback would be entertained? This is just the latest in a nearly endless list of issues with this truck. Just in the last month, the water pump, thermostat, starter and rear main seal have all been, or are in the process of, being replaced.

Overall, simply unacceptable at 64k.

 

I would wonder if you could get a new front axle at this point - the whole unit. Something is obviously wrong or the mechanics are incompetent.

 

Curious what the front diff failure symptoms are? Also is the truck stock?

 

I have a similar issue. Just had both IWE changed due to 4 wheel drive grinding, not working. That was $3200, dealer is west herr in webster NY. I got the truck, put it in 4a and gave it some gas, still hear noises and def not working correctly. I'm going back today to see what they say next. Do they not test drive?

I first went to west herr in Greece NY, they told me it was fine, go away, horrible dealer. I am now at another west herr (changing that next), and the service department seems to be better, but this will be visit number 2

I hope I don't make it to 5 visits, fix the freaking thing before calling me back.

 

I think you have a "Monday" built truck...maybe even the Monday after the Super Bowl build. Sorry to hear about all the issues you're having.

 

A grinding noise that you can both hear and feel. For me, it always sounds like it's coming from the front left area. It's not constant, but frequent. Same symptoms every single time. And yes, it's stock.

 

is the noise only when 4a/4h is selected or does it happen it 2h also? I assume 4a/4h, which is a similar issue I am having, from the front left as well. I have my 2nd appointment oct 31st, I'll report back

 

All of the above. I drive in 2H 95% of the time. When the tech and I took a test drive, he had me change the selector, I assume listening for a change. When there was noise in both 2 and 4, I can't understand why he still thought it was an IWE. Dealer is telling me another 1.5 weeks for this and the rear main seal to be finished.

Ford Customer Service has been an absolute joke.

 

I went for a drive along with my truck and the tech changed the **** and in my case there was quite a difference, so IWEs were changed. He said he can tell by the way they were or weren't engaging that there was an issue there. Interested to hear what your issue ends up being.

 

OP I am having the front diff rebuilt on my 21 Lariat right now as well. I am hoping to not have anymore problems after this. Truck was making the grinding/rubbing noise all the time and I changed the fluid that had lots of metal in it. I took pictures of the oil pan with metal in it and saved old fluid to bring with me. I got lucky that I only had to make one dealer trip before they said it would be fixed under warranty. I get the truck back this Friday. Oh and the truck was sold to me with the noise already happening but I did not notice on the day of the test drive Had the truck for almost 2 month and it has been sitting for almost 2 months.

They should replace the entire front diff including the casing.

Maybe it keeps failing due to the casing being bad inside where the bearing sit.