Ranger rear end problems.

[crazyrazor21]

So I'm writing this to help anyone else who is hearing some noise from their rear end. Starting last winter I began to hear a faint noise similar to tire noise but a different pitch. It would increase and decrease in volume with slowing and accelerating. After a few months, it became a howl. It was audible from the cabin as well as the outside, and was very very loud at this point. I had become accustomed to it as it had began small, thinking it was the very aggressive tires I have wearing down. Eventually, my buddy was riding with me and asked me about it. I said I had noticed it but the truck was working fine. (Quick basckstory, I sold the truck to myself, I was a salesperson for Ford for almost 2 years. My friend was as well. We are both car people and have built several vehicles. My Ranger is significantly modified aswell) This started my search for the problem. I began stripping off my wheels and spacers, looking at rotors, pads, calipers, U bolts etc as I had thought my tires wer rubbung or that something was rubbing on a moving piece of metal as it would increase with speed. I couldn't find anything. I combed over the entire rear axle several times, and at this point I knew it was something happening inside the pumpkin. This was obviously my worst fear, as my truck isn't stock. I was definetly concerned I was going to be in a fight with Ford's warranty department for months, as I've seen first hand how they can be. (I had a customer with a Raptor who was denied cam phasers by Ford, took him 4 months of back and forth before they fixed it) Thankfully, I knew several people in service from when I worked at the dealership, including the GM. In the end, Ford warrantied it and the entire axle housing was gutted and replaced.


I wanted to make this post mainly because I am lucky I was a former employee. Most people aren't in my situation. I hope I can help someone find the issue before their trucks warranty is out so they don't get stuck with a massive bill. ( Which you will see the final cost)



Cheers.

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[Muddy Fenders]

So were the gears the cause of the noise? Bad backlash?
Or was it a bearing?
Do you have any pics of the removed parts for closer inspection by us experts ?

 

[crazyrazor21]

So were the gears the cause of the noise? Bad backlash?
Or was it a bearing?
Do you have any pics of the removed parts for closer inspection by us experts ?

Sorry man, yeah I should've explained the main issue. Basically, the gears connecting to each axle are weak. The driveline center gear is actually a harder metal. So, in turn if the tires are not pefectly identical in height the center gear will start to eat away at the other two pinions. The tires on the rear were identical brands, model etc and were both put on at the same time. In fact, all my tires are. What the one tech had said is that Ford skimped out on these parts for cost reasons, thus even if the tires are milimeters apart in height it can cause this issue. The two side pinions are actually made in China as well, and took over 3 months to come in. Ford credit was actually making my payments during this time and extended my factory warranty to 136k miles for all drivetrain components. As for pictures, sadly these are all I have.

 

[Trigganometry]

Wonder how much of a difference there is between a locker and a stock rear end. Additionally if this issue is problematic with all or just one type… ?

 

[crazyrazor21]

Wonder how much of a difference there is between a locker and a stock rear end. Additionally if this issue is problematic with all or just one type… ?

I am not sure. I have the 3.73 locking rear diff.

 

[D Fresh]

The rear-end is made by Dana, not Ford.

Every person here who's had a rear end problem had the entire axle replaced by Ford odd that they rebuilt yours.

 

[D Fresh]

So were the gears the cause of the noise? Bad backlash?
Or was it a bearing?
Do you have any pics of the removed parts for closer inspection by us experts ?

Bearing and gear expert are you?

A job you take PRIDE in?

 

[crazyrazor21]

The rear-end is made by Dana, not Ford.

Every person here who's had a rear end problem had the entire axle replaced by Ford odd that they rebuilt yours.

We don't truthfully know that. GM has been slapping the Allison name on stuff they don't make, and I doubt that Dana is making their stuff in China. It is interesting however that they rebuilt mine if everyone has had the assembly replaced.

 

[D Fresh]

We don't truthfully know that. GM has been slapping the Allison name on stuff they don't make, and I doubt that Dana is making their stuff in China. It is interesting however that they rebuilt mine if everyone has had the assembly replaced.

It's a Dana 44. I've been intimately familiar with them for decades.

And I never understood why GM touts their Allison transmissions. Every one I've driven in our work trucks is steaming pile of shit.

 

[crazyrazor21]

It's a Dana 44. I've been intimately familiar with them for decades.

And I never understood why GM touts their Allison transmissions. Every one I've driven in our work trucks is steaming pile of shit.

You just made me spit out my coffee. Yeah my friend just ditched his colorad for a bronco. His colorado has had 2 transmissions, a rear end and 8 months with half his engine out in his garage trying to figure out why it wouldn't start. Needed an upper and lower fuse box, a starter, and an ignition switch. Things a 2018 v6 lt 4x4. Giant pile of crap

 

[Muddy Fenders]

Bearing and gear expert are you?

A job you take PRIDE in?

No no, just a google certified diploma here. Working on a masters degree with YouTube as an undergraduate.
I tried making a small windmill/water pump aerator for the fish pond last year. wasn't very efficient because the little gears i was using from an RC car were too tight. I actually spit out gear teeth after awhile.

 

[D Fresh]

No no, just a google certified diploma here. Working on a masters degree with YouTube as an undergraduate.
I tried making a small windmill/water pump aerator for the fish pond last year. wasn't very efficient because the little gears i was using from an RC car were too tight. I actually spit out gear teeth after awhile.

My wall is full of those Google Certifications!


The more we talk, the more I feel like I know you.?

 

[P. A. Schilke]

It's a Dana 44. I've been intimately familiar with them for decades.

And I never understood why GM touts their Allison transmissions. Every one I've driven in our work trucks is steaming pile of shit.

Hi Doug,

I recall Allison was bought by Roger Penske and is not part of GM anymore....

Best,
Phil

 

[D Fresh]

Hi Doug,

I recall Allison was bought by Roger Penske and is not part of GM anymore....

Best,
Phil

You're probably right.

I do know the ones in our milk trucks are highly sensitive to heat and many need rebuilds fairly quickly.

 

[Canadian Ranger]

Sorry man, yeah I should've explained the main issue. Basically, the gears connecting to each axle are weak. The driveline center gear is actually a harder metal. So, in turn if the tires are not pefectly identical in height the center gear will start to eat away at the other two pinions. The tires on the rear were identical brands, model etc and were both put on at the same time. In fact, all my tires are. What the one tech had said is that Ford skimped out on these parts for cost reasons, thus even if the tires are milimeters apart in height it can cause this issue. The two side pinions are actually made in China as well, and took over 3 months to come in. Ford credit was actually making my payments during this time and extended my factory warranty to 136k miles for all drivetrain components. As for pictures, sadly these are all I have.

When I bought my first rear wheel drive (2007 Ranger) in 2007, a very wise family friend and mechanic warned me about these implications in regards to the rear end. If I was ever to get a flat tire on the rear, to put a front tire on the rear, and the spare on the front. And that if there was big difference between the spare and original tire, it would 'tear the rear end out in the matter of a couple miles'. And to make sure if any new tires I bought were drastically different in circumference to the spare, to make sure I get a spare tire to match the four new ones.
This has always been the case with rear wheel drives, so to have your tech tell you Ford skimped out on the 5G rear ends, he was probably was correct (because they skimped out on many other details as well), but it would have happened to you eventually anyway. The mods are just as equally to blame, I'm guessing. New vehicles these days are engineered with very tight tolerances. Personally, I wouldn't mod my Ranger with anything other than from Ford or Ford Performance.

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