Rear Differential Failure on 2021 w/ 65K

[sejones3]

Bad news from the dealership on the noise that I was hearing from my 2021 XLT when letting up on the accelerator around 50MPH. Advisor reports it needs a new rear differential! From what I can tell from my internet and mechanic-friend research, it's likely a bad pinion bearing. No repairs on a diff? This is the second major driveline issue in this vehicle. The first was a serious (is there any other type?) transmission issue less than a year ago. That, thankfully, was fully covered under the powertrain warranty. After discussing the diff issue with Ford Customer Assistance, they agreed to help with the cost, but it's looking like two+ weeks to get a new differential and almost $2K from my pocket. I love this vehicle, but hate that Ford can't seem to get their act together.

 

[hbalek]

Bad news from the dealership on the noise that I was hearing from my 2021 XLT when letting up on the accelerator around 50MPH. Advisor reports it needs a new rear differential! From what I can tell from my internet and mechanic-friend research, it's likely a bad pinion bearing. No repairs on a diff? This is the second major driveline issue in this vehicle. The first was a serious (is there any other type?) transmission issue less than a year ago. That, thankfully, was fully covered under the powertrain warranty. After discussing the diff issue with Ford Customer Assistance, they agreed to help with the cost, but it's looking like two+ weeks to get a new differential and almost $2K from my pocket. I love this vehicle, but hate that Ford can't seem to get their act together.

I've had my differential replaced at 50K miles and at 58K miles I'm on my third one. Also my third transfer case. Fortunately all under powertrain warranty. Now I'm on ESP so it will cost me $100 deductible. I'm definitely not keeping it after the warranty ends. I also had the FADA TSB last year along with transmission rebuilt at 25K miles. At one year old had the fuel pump replaced and around 3 years old had the catalytic converter replaced. The engine has been bulletproof though. Now I'm told that at 58K miles I'm at half-life on my original brake pads! So I have to say the good with the bad! I still love it despite all the problems I've and had to remind myself the fact that all my repairs were done free of charge.

 

[Ironworker40]

There is very few mechanics these days that can set a rear diff up properly. For $600 that the whole unit costs you're probably better off anyway. Sucks that you're out of powertrain warranty.

 

[sejones3]

I've had my differential replaced at 50K miles and at 58K miles I'm on my third one. Also my third transfer case. Fortunately all under powertrain warranty. Now I'm on ESP so it will cost me $100 deductible. I'm definitely not keeping it after the warranty ends. I also had the FADA TSB last year along with transmission rebuilt at 25K miles. At one year old had the fuel pump replaced and around 3 years old had the catalytic converter replaced. The engine has been bulletproof though. Now I'm told that at 58K miles I'm at half-life on my original brake pads! So I have to say the good with the bad! I still love it despite all the problems I've and had to remind myself the fact that all my repairs were done free of charge.

And so the dilemma, the good with the bad. The good is really good and the bad is very close to unacceptable. My previous Explorer ('08, 275kmi) had a transmission repair, but not until 150k. Other than the normal stuff, it was a great mechanical vehicle. This one, not so much. Your comment about not keeping it beyond the ESP is sound advice. Since I don't have the ESP, I'm debating my options. If money were no object, it would be gone. The warranty costs have to be killing Ford as much as their poor decisions on EVs.

 

[sejones3]

There is very few mechanics these days that can set a rear diff up properly. For $600 that the whole unit costs you're probably better off anyway. Sucks that you're out of powertrain warranty.

Yes, it sucks, big time. More and more major components are falling into the "few mechanics can fix properly" category as you suggest. Dealer quote for the replacement was just north of $3600 (crazy). Essentially, my out-of-pocket was the same whether I went to the dealer or a local shop. Since it was already at the dealer, I had them do it. Still there. They are also replacing the transfer case seal which is starting to leak. I'm kicking myself as I had heard a slight noise starting a about 10k miles ago, when it was still under warranty.