23K Miles - Differential Leaking 2021 F150

[imnuts]

Thank you. I looked up the procedure for checking the fluid level in the service manual and it is easy enough to do, but not something I'm tackling in the dark. For anyone else that needs it, the front diff fluid level should be within 3mm of the fill plug if the truck is level. The procedure didn't mention if that was cold or hot that I saw though.

I also happened to review the troubleshooting items for the front diff, and both items I mentioned show up in the "complaint" section. It annoys me even more now that they didn't check the differential again after they worked on it and I stated specifically that the noise is coming from that area and the sounds I heard are in the factory service procedures.

I'd still appreciate if anyone else could confirm or deny shaft play on the diff input.

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[fordtruckman2003]

Warranty fix when I bought truck with leaky differential. I don't have any noise from mine. I plan to check fluid level in warm weather after a winter of 4x4 use. If it breaks ESP will deal with it. I definitely plan to change oil earlier than Ford schedule since it's been opened up once already.

 

[imnuts]

I drive my truck to/from work on Thursday, and it progressively gets worse as the drive continues. I also ended each leg of the work journey in 4A, which sounded horrible. I checked the stuff fluid Friday morning and it may actually be a little overfilled, but the fluid also smells like it overheated. Called the dealership, took it in and rode with the shop foreman.

He could hear the whining noise, but not the knocking, then we switched sides and he could hear it. I left it with them Friday and got a call just before they closed that they've narrowed it down to something in the drivetrain, but not fully pinpointed yet. Even though running in 4A made it worse, I think that was the ticket to get them to investigate the noises further.

So, I have a loaner again while they diagnose and put a parts list together. Not sure how long it will be, but it sounds like it'll be a costly warranty repair from when I picked up the loaner. Now I have a frunk for a few days.

 

[notabot]

Now I have a frunk for a few days.

@imnuts
That's a lot of Downy my friend!!!!!!! FWIW, if you use wool dryer balls you can get rid of that smelly stuff...

 

[imnuts]

Called the dealership this morning looking for an update. They determined the pinion bearing needs replaced, but parts should be in next week. Searching, this seems like it could have been coincidental in timing with the seal repair, but I'm not sure. I did find this thread with others that have had similar issues, but most there seem to have a lift/level. The Lightning has been good thus far, and I'm glad the find the issue and a repair is in progress. I'm wondering if they're part delivery estimate will hold or not though as the seal that was replaced was 3-5 days and ended up being more like 5-6 weeks.

 

[dzacco]

So, I was waiting to post again, hoping the dealership would address my concern. I picked my truck up Friday, I noticed a slight whirring noise driving home, but nothing major. Drove around Saturday and didn't notice anything odd at all, but with the snow that hit the area, I did do a decent amount of travel in 4A and definitely put it to use in later in the evening. Drive to work Monday morning, and the whirring is almost a whining noise now.

I thought it was maybe a liner that fell or snow rubbing the tires, so I checked when I got to work and nothing. Call the dealer and they agree to look at it. Drive to the dealer, the whirring/whining is still there, and now I notice a knocking sound from ~45-55 mph (± 5). After riding with a technician and then "manager", they agree to give me a loaner and look at it.

No update Tuesday, but given the weather, they may have been prioritizing other vehicles. Call today and they say all is good, no more noise. Whining may just be tires (they are worn, but tire noise doesn't come out of nowhere). I pick it up this evening, and the whining is still there and so is the knocking.

They said the knocking was just something caught in the air dam. I check the air dam tonight and nothing is in there. My thought is that when they replaced the seal, they forgot the gear oil, and with all the 4A action on Saturday, it ran that entire time without lubrication and is now toast. When driving with the manager, I was in the passenger seat, and the knocking wasn't as noticeable, but you could feel it on the passenger side, where I could only really hear it on the driver's side.

I checked the shaft from the transfer case to the front diff tonight as well. There is zero play on the transfer case end, and some play on the front diff side, maybe a 1/16"? Is anyone willing/able to check the input shaft to their front diff to see if there is any movement for me? I want to try and get as much info as I can before I call the dealership back tomorrow. Also, is there a way to check the front diff fluid level without draining it?

 

[dzacco]

I drive my truck to/from work on Thursday, and it progressively gets worse as the drive continues. I also ended each leg of the work journey in 4A, which sounded horrible. I checked the stuff fluid Friday morning and it may actually be a little overfilled, but the fluid also smells like it overheated. Called the dealership, took it in and rode with the shop foreman.

He could hear the whining noise, but not the knocking, then we switched sides and he could hear it. I left it with them Friday and got a call just before they closed that they've narrowed it down to something in the drivetrain, but not fully pinpointed yet. Even though running in 4A made it worse, I think that was the ticket to get them to investigate the noises further.

So, I have a loaner again while they diagnose and put a parts list together. Not sure how long it will be, but it sounds like it'll be a costly warranty repair from when I picked up the loaner. Now I have a frunk for a few days.

How are you charging that thing?

 

[imnuts]

How are you charging that thing?

I charged it at work and also had charging stations ~5 min from home. I could have also gone to the dealership which was ~15-20 min away if I wanted, but never needed to.

 

[mflynndelta]

I have a 2021 F150 that just rolled 23k miles and it has a decent leak where the driveshaft goes into the back of the front differential.

Took it to my local Ford Dealership for warranty work and they said “yeah, it is leaking, but not enough that Ford will reimburse us for the work so we won’t repair it unless you want to pay us to repair it”

See attached pictures and quick video.

At what point is it considered a decent leak? It has an active drip after any driving.

I am having the exct same leak ? Did your dealer ever fix this ? I have 52k miles ahould this be covered under the powertrain warranty ?

 

[mflynndelta]

Warranty fix when I bought truck with leaky differential. I don't have any noise from mine. I plan to check fluid level in warm weather after a winter of 4x4 use. If it breaks ESP will deal with it. I definitely plan to change oil earlier than Ford schedule since it's been opened up once already.

how many miles do you have now ? mine has 52k is this covered under powertrain warranty ?

 

[fordtruckman2003]

how many miles do you have now ? mine has 52k is this covered under powertrain warranty ?

I would assume it would be covered under powertrain but you would need to refer to Ford warranty documentation. I have premium ESP that will cover it.

 

[mflynndelta]

I have a 2021 F150 that just rolled 23k miles and it has a decent leak where the driveshaft goes into the back of the front differential.

Took it to my local Ford Dealership for warranty work and they said “yeah, it is leaking, but not enough that Ford will reimburse us for the work so we won’t repair it unless you want to pay us to repair it”

See attached pictures and quick video.

At what point is it considered a decent leak? It has an active drip after any driving.

I am curious what was the resolution for this from Ford ? I have a similar leak from the same place.

 

[fordtruckman2003]

I am curious what was the resolution for this from Ford ? I have a similar leak from the same place.

Seal gets replaced under warranty assuming you are within miles the powertrain warranty will cover it. Seals fail, it happens, mine was fixed and I'm not concerned about it.

 

[mflynndelta]

Seal gets replaced under warranty assuming you are within miles the powertrain warranty will cover it. Seals fail, it happens, mine was fixed and I'm not concerned about it.

thank you so much ....I will update after Tuesday

 

[mflynndelta]

thank you so much ....I will update after Tuesday

Repair has been completed by dealer and it was covered under warranty.

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