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Transmission grinding and won't drive in 2h

lamy

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I bought 2 x 2021 Powerboost XLT's with Max Tow in 2021 for my business (they have consecutive vin numbers). One of them has already had the transmission replaced under warranty at about 30k miles. The other truck (my daily driver) has had hard shift issues from the beginning and I am on my third axle bolt replacement. Over the last week the transmission started making progressively louder clanks when shifting. While driving down a busy highway, my transmission started grinding and I rolled to a stop in the center turning lane. The grinding stopped when I put it in neutral, but would start again when I attempted to put in reverse or drive. I went into 4h, and was able to shift and drive. I'm currently driving around in 4h, and have an appointment at my dealership later this week. I have not been hard on the truck at all, and only towed a small trailer a couple times.

I don't have any faith in my dealership's service department at this point, as I have brought my truck in multiple times over the past year to address various drivetrain noises it was making, and they have never been able to pinpoint any issues. Recently, my truck has been making a squealing sound that I reported (and mentioned in another thread on this forum), but they couldn't get me in for over a month. I guess all it took was my transmission dying for them to jump on it.

I assume, at this point, that it is a transfer case issue. Is there anything else I should be concerned about, that would be worth mentioning to the service manager?

Thanks!!
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Gros Ventre

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My inference from your description is that the problem lies in the transfer case output to the rear axle. I'd bet the rear propeller shaft is not driving the rear axle now. So effectively you are in 2WD on the front axle... If you haven't taken it in yet jack up the rear end and crawl under and see if you can spin the rear propeller shaft independent of the front.
 
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lamy

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That is what it feels like. I don't get the usual rear end grip/skid when turning on dry pavement in 4wd. I will jack it up tonight and take a look.
 

Gros Ventre

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That is what it feels like. I don't get the usual rear end grip/skid when turning on dry pavement in 4wd. I will jack it up tonight and take a look.
Good luck... I'm wondering, I changed out my engine, transfer case, and both axles way early. The front axle lube drained out was awful looking and not even sure that it was lube... So maybe you got some of that stuff... Just wondering. I change out my lubes early in order to reduce the amount of manufacturing debris left in the components.
 

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HammaMan

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Sounds like a rear axle spline strip event, not related to the trans. The fact you've had so many broken bolts points to an issue with the rear end itself. I'd try and get them to replace the entire rear axle housing and its related parts.
 

JExpedition07

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Sounds like your rear differential is gone my friend
 

Ford Motor Company

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I bought 2 x 2021 Powerboost XLT's with Max Tow in 2021 for my business (they have consecutive vin numbers). One of them has already had the transmission replaced under warranty at about 30k miles. The other truck (my daily driver) has had hard shift issues from the beginning and I am on my third axle bolt replacement. Over the last week the transmission started making progressively louder clanks when shifting. While driving down a busy highway, my transmission started grinding and I rolled to a stop in the center turning lane. The grinding stopped when I put it in neutral, but would start again when I attempted to put in reverse or drive. I went into 4h, and was able to shift and drive. I'm currently driving around in 4h, and have an appointment at my dealership later this week. I have not been hard on the truck at all, and only towed a small trailer a couple times.

I don't have any faith in my dealership's service department at this point, as I have brought my truck in multiple times over the past year and driven around with the service manager to show him the various disconcerting noises it was making, and they have never been able to pinpoint any issues. Recently, my truck has been making a squealing sound that I reported (and mentioned in another thread on this forum), but they couldn't get me in for over a month. I guess all it took was my transmission dying for them to jump on it.

I assume, at this point, that it is a transfer case issue. Is there anything else I should be concerned about, that would be worth mentioning to the service manager?

Thanks!!
Hi there. This transmission concern doesn’t sound like something we want you to experience with your F-150. Could you please send us a PM with your VIN and the name and location of your Ford dealer? To send a private message, just click on our username and select "Start Conversation". I'd be happy to look into how I can assist you on my end.
 
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lamy

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Thanks for all the input guys! @Gros Ventre, when I first bought the trucks, I remember reading on this forum about rear diff fluid issues, maybe I should have paid more attention.

@Ford Motor Company I'm sending a PM now.
 

Gros Ventre

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I change out fluids early, early... Just on GP, but primarily to get out some manufacturing residue... When I dumped the front axle on my '21 F150, I just did not like what I saw... So glad I did that.
 

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Eff0neFitty

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Samson16

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Thanks for all the input guys! @Gros Ventre, when I first bought the trucks, I remember reading on this forum about rear diff fluid issues, maybe I should have paid more attention.

@Ford Motor Company I'm sending a PM now.
I don’t think it was fluid. I think Hamma mentioned your 3 sheared axle bolts as a clue. I don’t know much but sheared axle bolts are a red flag 🚩
 
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lamy

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Curious, did this "Ford Motor Company" ever get back to you and really do anything? @Ford Motor Company
They did get back to me, and so far they asked me to bring my truck into the dealer to diagnose the issue. Not sure if there has been anything else done from their side beyond that.

For now, my truck is stuck at the dealership for at least a week, while we wait for the parts to come in. I expressed concern to the dealership about the axle bolts being a recurring issue and asked if they could replace the entire axle housing/assembly. They said they would just follow the TSB, which I assume will be to just replace the shafts, and in my case, swap out the destroyed diff internals.
 
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lamy

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Thought you guys might like an update.

I have now been without my truck for 20 days. The parts are backordered (not sure which parts specifically). Ford assigned me a truck "specialist", who supposedly expedited the parts order early on, but has not responded to any of my requests/questions since. My dealership does not have any loaner vehicles. Ford will only provide $60/day for a rental and it has to be a Ford truck, which are not available in my rural area. Needless to say, this has not been a great experience. I will be going with a GMC or Toyota for my next truck (I had similar recurring issues with a RAM 1500 and faulty/weak manifold bolts).
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