Photos Oil leaking from FADA, options?

[blackstallion]

Noticed the leak originating from the axle transfer case while completing my last oil change.

After some digging today, found tsb 23 - 2174, which seems to be the solution (sounds like it should really be a Ford recall!)

No light yet on the dash, BUT I'm at 103k and no extended warranty, so I feel it's a matter of time.

What are the options? Are there any bandaid fixes for now to stop the literal oil bleeding?

I'm assuming Ford will charge thousands to replace with the new Assy, without taking financial accountability, is it even worth wasting my time going to a stealership?? Anyone have the cost from Ford to complete the job?

What about private mechanics, can they successfully complete this job since the SW needs to be updated as well?

 

[themishmosh]

I externally sealed the FADA leak. The TSB you listed is not for the leak, but I suspect when all the front diff oil drains out and the FADA fails. In any case, since you ae out of warranty, i would try sealing it up from the outside. First, drain the front diff oil so oil stops oozing out. Spray brake cleaner at the mating area. Once dry, use Gasket sealer (i used red Permatex IIRC) and apply with your finger. Make sure you allow sufficient time to cure. The upper surface you will not be able to reach. Use spray sealant at this point (again, I used Permatex) and make multiple coats, allowing for sufficient dry time. This has been good for me for 3 years and over 40k miles and counting. When done, refill the front diff. If you haven't done so, Id use the time to replace all drivetrain fluids if you have the car up on jackstands.

Edit: Additionally, I noticed you have the 2.3L ecoboost. Doing the TSB yourself is actually doable as a DIY. The 2.3L does not need the left motor mount removed which makes it a breeze. Maybe $5-600 in parts. You will need to flash the AWD module using FDRS to specify that you no longer have the electronically controlled FADA.

 

[blackstallion]

I externally sealed the FADA leak. The TSB you listed is not for the leak, but I suspect when all the front diff oil drains out and the FADA fails. In any case, since you ae out of warranty, i would try sealing it up from the outside. First, drain the front diff oil so oil stops oozing out. Spray brake cleaner at the mating area. Once dry, use Gasket sealer (i used red Permatex IIRC) and apply with your finger. Make sure you allow sufficient time to cure. The upper surface you will not be able to reach. Use spray sealant at this point (again, I used Permatex) and make multiple coats, allowing for sufficient dry time. This has been good for me for 3 years and over 40k miles and counting. When done, refill the front diff. If you haven't done so, Id use the time to replace all drivetrain fluids if you have the car up on jackstands.

Edit: Additionally, I noticed you have the 2.3L ecoboost. Doing the TSB yourself is actually doable as a DIY. The 2.3L does not need the left motor mount removed which makes it a breeze. Maybe $5-600 in parts. You will need to flash the AWD module using FDRS to specify that you no longer have the electronically controlled FADA.

I would definitely be interested in exploring the DIY route, but have some questions.

1) Know of any good online resources that either show someone performing this job, OR, a manual that explains the process to replace the FADA with the new intermediate shaft?

2) FDRS and the need for the associated Mongoose cable (which I don't have) is ~$600, so on top of whatever the new intermediate shaft cost is, could bring my DIY cost closer to ~$1k?

3) I'm guessing Ford service wouldn't want to reprogram if they didn't perform the FADA delete; I can ask some local shops if they maintain an FDRS or similar capability, but what are my options for reprogramming? Would the vehicle be safe and driveable with those codes until I reprogrammed?