Cracked Front Diff Housing

[Rippy]

I've thought about this one... Unless you somehow whacked the case on a rock (pretty difficult I think!), or pounded it yourself with a big hammer (really?), there is just no way it can be anything other than a casting flaw... Nothing elase adds up. Ford needs to stand up on this one and just give you a new differential.

That would be (2) casting flaws, as they have replaced the differential housing and the new one is leaking badly. Maybe three is the charm?

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[Grottos]

I made a account just to throw my hat In the ring! Went to pull out of my snow covered driveway today and as I pressed the 4h button a loud bang followed closely by gear grinding. Crawled under to see my housing wide open with large chunks of it in the snow. Hopefully ford will have a look tomorrow.
This is a work truck, completely stock with 40,000 km on it. The puddle of fluid was grey not clear, so I assume it’s been grinding something before the failure.

 

[Gros Ventre]

I changed out my differential fluid shortly after taking my truck home. Took a bit as I had to get my hands on a vacuum extractor given the very tight location. The drained fluid was an opaque gray, no chunks or such but I really didn't like its color. Been runnning fine since and I use it frequently out my way (western Wyoming). Note: this opaque gray color was in contrast to the rear adifferential. That gear lube was of a normal brown/tan translucent coloration.

 

[SRHAGEN]

I changed out my differential fluid shortly after taking my truck home. Took a bit as I had to get my hands on a vacuum extractor given the very tight location. The drained fluid was an opaque gray, no chunks or such but I really didn't like its color. Been runnning fine since and I use it frequently out my way (western Wyoming). Note: this opaque gray color was in contrast to the rear adifferential. That gear lube was of a normal brown/tan translucent coloration.

Could water be intruding into the case? Opaque usually means contaminated.

 

[Gros Ventre]

Could water be intruding into the case? Opaque usually means contaminated.

Had no separation of water & gear lube, even after extanded stand time. Good question but I don't think so.

 

[hotrodmex]

Went to pull out of my snow covered driveway today and as I pressed the 4h button a loud bang followed closely by gear grinding

Had you even started moving? Or where you engaging while moving?

This failure is in a different spot than has been seen.

 

[Grottos]

Had you even started moving? Or where you engaging while moving?

This failure is in a different spot than has been seen.

I wasn’t moving but the rears were slipping. I remember being confused for a second that I was spinning in 4h just before it popped. So I must of pressed 4h then applied throttle just long enough to confuse myself. And when I say applied throttle I wasn’t gunning it. Just like a normal pulling out of driveway acceleration. It’s a 8ft box regular cab so it’s very common the rears don’t get any traction in snow. I’ve done that same thing in that spot whenever there’s snow and here that’s about 5 months a year.

and Il add there was no signs of a leak like others with a crack have said.

 

[SRHAGEN]

Had no separation of water & gear lube, even after extanded stand time. Good question but I don't think so.

Thanks

 

[Grottos]

Quick update, the ford dealer said the axels were the only thing holding the front differential on, it had ripped off the frame. They think the housing had cracked near the mount and it finally let go causing the driveshaft to bind and tear off the housing. Fixed everything under warranty but it definitely leaves a bad taste in my mouth…

here’s a picture the dealer sent me once they got the diff out.

 

[Rippy]

Quick update, the ford dealer said the axels were the only thing holding the front differential on, it had ripped off the frame. They think the housing had cracked near the mount and it finally let go causing the driveshaft to bind and tear off the housing. Fixed everything under warranty but it definitely leaves a bad taste in my mouth…

here’s a picture the dealer sent me once they got the diff out.

I dropped mine off at the dealership for front differential number 3 today. Hope they grab one from a different bin this time. Been a real pain!

 

[Clayton Gehring]

Just had this happen to my 2021 f150 xlt sport. Was spinning in snow and bang lost 4 wheel drive. Dealer says they don’t know if this will be covered under warranty as they have never seen this before. So currently waiting to see if Ford Canada will honour it. Also a new one is 3 weeks away.

 

[Rippy]

How many miles on it?

 

[Clayton Gehring]

How many miles on it?

just under 18000km

 

[amschind]

The VAS part looks awesome, but there is no way to run it with a Talons skid plate package (I confirmed this with VAS). Both companies are in Houston, so I've asked both to see if they can make any changes that would allow both to work together. I'll keep everyone posted if I learn something.

 

[Rippy]

If the original differential housings are made of peanut brittle and the replacement housings are made of peanut brittle, what are you supposed to do?

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