2009 Explorer 4x4 front diffs

[SBV45]

I just heard from the job shop that I took my front diff for overhaul, that they have recently had 6 front diffs from Ford Exploders and Expeditions in the similar years. The cited carrier bearing problems and possible gear failure.

 

[Town]

Your problem with such a new vehicle is such a shame. Is the cause known? Does the shop figure an oil related problem or something else?

Does the problem affect earlier models such as the 2006, 2007 and 2008?

 

[4df150]

Inquiring minds want to know....

 

[SBV45]

Don't know yet. They just said in similar year. I'll try to find out more.

There is no problem identifying the problem. You will get a rubbing/grinding vibration that you can feel in the steering wheel. The front hub bearings were gone also. I thought it was the hub bearings but changed those out and the rubbing/grinding vibration was still there. You could cruise along at different speeds and it would go away, change speed or decelerate and it would come back.

Austin Drivetrain/Inland Truck Parts checked it out before I had the diff moved and that is when they commented that they had 6 similar. I will try to get more info.

 

[SBV45]

I got the front diff back. It was the carrier and pinion bearings. No metal at the bottom of the case. Gears were okay.
I wonder where Ford is sourcing their bearings.
I have it all back together and runs good.
It should.

 

[jrford]

i've got a noise in the front, . might also be the same problem as you.
Low drone noise 45 get obvious 70-80mph, doesn't change with RPM's.

Its in the shop now. .waiting to hear back.

Would it be covered by the Powertrain Warranty? I've got 5k left before i hit 60k.

Edit: expert trans guy is leaning more towards a bad wheel bearing. . .figures.

 

[SBV45]

Now that I have it all done, I can better describe the experience. The front diff carrier and pinion bearings was most noticeable as a grinding or rubbing sound that could be felt in the steering wheel. Understand that I am deaf as a post and I don't hear high frequency noises very well. At first the front wheel hubs problem masked some of the noise from the differential, but after having the hubs replaced the diff noise was very noticeable. All the noise/rubbing/grinding was 40 to 65+.

Now it is nice and quiet, I think.