Front Diff Pinion Bearing Failure

[Navigator]

Seems it would have been easier to swap the differential. How did bolts get cross threaded was there prior work done?

I think it would have been much easier and faster to find a skilled mechanic to swap it out for a new or reman unit. It would have been more expensive but I needed the truck for work reasons. The dealership made this look like a science experiment. I have seen major engines opened up and transmissions swapped out which took a lot less time. It seemed like the dealership was launching a space rocket rather then simply fixing the truck. This really set me back.

I picked up the vehicle in February new and put 20,000 miles on it. No work was ever done to it. I have had 2 similar vehicles in the past where this was NEVER the problem. The problems in the past were engine, cooling and transmission. Those problems appear to have been solved. However, this is a new issue.

I am not savvy to front differentials. Are there units from Ford performance or some other maker of differentials that would be better to put in there?

My strong advice is be particular about the dealership you take it to. If you had problems in the past with the dealership then go to another one. Look at reviews closely. If there any reviews about bad service or untimely repairs forget that dealership. Its not going to work. Part of this was my fault because I had issues with this dealer in the past and should have known better. Yeah...maybe you should entertain an independent mechanic and find a better differential if one can be found.

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[scott011422]

I"m going to have to look at mine with a thermal camera. I have an odd vibration / noise that reminds me of a WWII bomber movie. Rotating tires made no difference. I can shift into N and turn off the engine @ 50mph and I can still hear it, so not engine noise. I find it far from normal. Also, being a 22' I don't have IWE's, so my front axle is always turning. Definitely something to look at.

 

[WhiteLightningnshitshadow]

I"m going to have to look at mine with a thermal camera. I have an odd vibration / noise that reminds me of a WWII bomber movie. Rotating tires made no difference. I can shift into N and turn off the engine @ 50mph and I can still hear it, so not engine noise. I find it far from normal. Also, being a 22' I don't have IWE's, so my front axle is always turning. Definitely something to look at.

Maybe. Do you have the 4A option? The XLT and lower have EIWEs. Sometimes these have trouble disengaging in cold weather.

 

[scott011422]

I do have the 4A option, Only use it when the roads are not snow plowed though. I could be wrong, I was under the impression that they took the IWE's off all versions in 22?

 

[Snakebitten]

I believe it's only the 4A equipped trucks eliminated IWE's. And perhaps not even all of those?

 

[hotrodmex]

'21-? 4A, ESOF and 4A Hi-Lock (Tremor): IWEs

'22+ 4A: no IWEs

 

[Gros Ventre]

I've been reading these entries. Just doesn't make sense (uless there's a manufacturing defect)... I think the change in angle when lowering has something to do with this since that changes the angle of entry of the shaft into the casing. You wouldn't think a small change in this angle could do that... but maybe it changes the oil circulation within the casing and the bearing drys out... Hm-m-m...

 

[hotrodmex]

I've been reading these entries. Just doesn't make sense (uless there's a manufacturing defect)... I think the change in angle when lowering has something to do with this since that changes the angle of entry of the shaft into the casing. You wouldn't think a small change in this angle could do that... but maybe it changes the oil circulation within the casing and the bearing drys out... Hm-m-m...

Leveling kits don't change the position of the front differential at all. It changes the angles on the CV axles, but main diff housing is untouched. Only if you do a full 4" lift does the diff have to move.

 

[Sean80]

Reviving old thread here…

I have 2022 401a Tremor with torsen, 2” dealer installed level kit, and 295/60r20 tires on +20 offset wheels with 44,000kms.

I have noticed a gas pedal vibration develop over the last couple of months which is getting progressively worse. I notice it when turning at an intersection left and right, and now get some vibration when driving 40-50km/hr. Took it to a dealer who confirmed the vibration, but told me to put the truck back to stock before they would do any further trouble shooting. You can only feel it when on the throttle, no vibration when coasting off throttle.

With the dealer being of no help whatsoever, I’m thinking of taking the truck to a 3rd party mechanic to determine the issue. Pretty sad, but I’ve got to do something or I’ll be stranded somewhere one day. Also doing my own research trying to determine the cause and came across this thread. Do my symptoms seem to match what was experienced here?

Thanks for any help. Lucky for me I leased it, so I’ll be giving it back if they can’t fix it.

 

[Monello96]

I’ve been having the same vibration / whirring sound that comes and goes. Finally had the dealer look at it- front diff pinion bearings - medal shavings were discovered and they will be replacing the guts of it.

2021 lariat 3.5 with 4a

 

[Coletrickle]

Reviving old thread here…

I have 2022 401a Tremor with torsen, 2” dealer installed level kit, and 295/60r20 tires on +20 offset wheels with 44,000kms.

I have noticed a gas pedal vibration develop over the last couple of months which is getting progressively worse. I notice it when turning at an intersection left and right, and now get some vibration when driving 40-50km/hr. Took it to a dealer who confirmed the vibration, but told me to put the truck back to stock before they would do any further trouble shooting. You can only feel it when on the throttle, no vibration when coasting off throttle.

With the dealer being of no help whatsoever, I’m thinking of taking the truck to a 3rd party mechanic to determine the issue. Pretty sad, but I’ve got to do something or I’ll be stranded somewhere one day. Also doing my own research trying to determine the cause and came across this thread. Do my symptoms seem to match what was experienced here?

Thanks for any help. Lucky for me I leased it, so I’ll be giving it back if they can’t fix it.

My 2021 Tremor is at the dealership right now for the 2nd time for this same issue. Noise was only there in 4A or 4H and under a load/acceleration. First time it was in the dealer they rebuilt the front diff and replaced both front axels. They told me the diff fluid was silver then. This was less than 4,000 miles ago that the work was done. The noise was never gone but I took it back and decided to drive it anyways. I may be used 4A a couple times to see if the noise was there in the last 7 months (so 2H 99% of the time) and I finally took it back into the dealer to have them check it again. They called me today and said the front diff needs to be rebuilt again and the fluid was silver. They have no idea what is causing this. I do have a Level kit (Eibach springs and struts level kit for the Tremor specifically) on it and running 285/75R18 on stock wheels.

Ill update what they find when I know more.

 

[JacobH]

Is this really a week or two repair? My truck had the grinding and vibration too but I was told it was just the pinion bearing that failed and no other damage. Dealer has had my truck for over 2 weeks now since dealing with tech shortage and warranty approval. They got the parts 2 days ago and supposedly started the work, kinda hard to believe the repair would take more than 2 days....

 

[Micho523]

My 23 Lariat 2.7 with 4A had the front differential assembly replaced at 26k miles. Stock ride height, no leveling or lifting. Same story as everyone else, bearing noise and vibration in the pedals. I only use 4A at the boat ramp, no abuse. Took two weeks to get done, dealer told me the assemblies are made to order.

 

[Papaw2018]

I’m adding my KR to this perpetual saga. 42k on my 2022 KR 5.0 and front diff is getting rebuilt this week. Vibration in floorboard and pedal with noise up front was noticeable at 39/40mph-+. All fluids had been replaced many months ago and then all the sudden > low noisy growl Up front. One dealer told me it was my tires and yes, I could use some new ones. So new tires mounted> same growl and vibe. Another dealer performed a complete evaluation and found my issue.
I have a NEW Dealer of choice from here on out .
Enjoy>

 

[Papaw2018]

Just wondering here

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