2023 Ranger broken steering gear and differential blown

[Morgangwc]

So, my new 2023 Ranger with 6,400. miles went into limp mode. I limped into the dealer, the truck was shuddering and had no power steering, only to be told the steering gear was bad and they needed to rebuild my rear end due to large shards of metal inside both sides of the differential! WTF. How does this happen to a 4 month old truck?
Between the spongy brakes, the transmission issue it's starting and a issue with an oil leak due to the oil filter not being installed correctly from the factory I'm really beginning to lose faith. My 2020 had a couple of issues (brakes and trans went south) but it was trouble free for 100k miles..until the trans finally stopped shifting from 6-8th gears.
Has anyone one else had the differential issue?

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[2020FX4]

Ouch..... That is not fun! Hopefully they can get these things fixed right for you and you won't have anymore issues. Sorry to hear about your truck.

 

[Wytchdctr]

That is a weird mix of holy crap. Maybe it will get all of its BS out of the way early on.

 

[P. A. Schilke]

So, my new 2023 Ranger with 6,400. miles went into limp mode. I limped into the dealer, the truck was shuddering and had no power steering, only to be told the steering gear was bad and they needed to rebuild my rear end due to large shards of metal inside both sides of the differential! WTF. How does this happen to a 4 month old truck?
Between the spongy brakes, the transmission issue it's starting and a issue with an oil leak due to the oil filter not being installed correctly from the factory I'm really beginning to lose faith. My 2020 had a couple of issues (brakes and trans went south) but it was trouble free for 100k miles..until the trans finally stopped shifting from 6-8th gears.
Has anyone one else had the differential issue?

Hi Morgan,

I have never in my 30 years at Ford Truck seen something like this. Please attach a copy of the Ford Dealer Repair printout of the repairs...very hard to imagine so much happening to one truck so soon... Ford quality is very concerning to me now.

Best,
Phil

 

[Frenchy]

Definitely a surprise here. It is the first I have heard of as well. One thing is for sure, Ford will definitely need to cover this. If they try not to I would try to get the good old L word involved, but only if Ford insists they won't cover it. As for Phil's comment, I agree unfortunately.

 

[9zero1790]

wow im surprised. i hope they get it fixed up and no more issues come up.

 

[Stevedbvik1]

Sorry to hear about all your troubles. I haven’t had any diff problems other than at 3200 miles having to change the fluid. Filthy with heavy fuzz on the magnet and a bunch of small flakes. Drained it and flushed as much as I could with brake cleaner. It’s been fine ever since and I’m at 15k now. I have a Tremor with the locker.

 

[DukeCanBuildit]

Customer: My power steering isn’t working.

Dealer: Hmmm, we better check the rear end.

I’m skeptical OP. I don’t think even the worst dealer would do that. Something smells, here. Not a fishy small…more like a TuRD smell.

Maybe I just need my second morning coffee.

 

[GManRanger]

That is a weird mix as previously said… Steering, & then discovered the bad rear diff.
(You weren’t by chance driving around on pavement with rear locker engaged were you?)
Whatever the case, no mech issues are fun with a new vehicle. My ‘23 XLT/FX4 is first Ford & first new vehicle ever at age 60 (not counting 12 motorcycles, 3 of those new.)
I was over-zealous to nurse the Ranger’s break-in… brought it home & checked every connection for snugness (batt cables were loose… tightened & greased.) Connected a smart-charger overnight, then let it sit for 6hrs as the manual outlines.
Grandpa driving for 1500mi, yet did cycle the trans thru all modes & worked the 4H/4L & Rear Locker on my 1/2mi unpaved steep road daily. Big believer that ALOT of break-in happens the first 1-2K miles.
At 1500mi… changed ALL fluids:
Oil/filter
Both diffs the fluid was brown & goopy!
Transfer case with LV fluid, not ULV per manual.
Trans per service manual got it to temp (200+) and checked (yes a PITA procedure!) & found it 1qt low. Dropped pan with friend help and installed the PPE pan. Filled to spec with ULV fluid.
At 5000mi… Repeated all above (over-zeal I know) …the diffs were much cleaner; now I’m confident all break-in junk is flushed out. BTW, I followed advice of another on here & used Motorcraft 80W90 mineral lube vs any brand full-syn. Research the reasons why. And I added the AFE Diff cover holding 0.7qt more fluid.
The trans was easy with the drain plug & magnet showed very little metal. Measured 6.7qts out & added the same new ULV.

All that just for peace of mind after dropping 40K for the new ride.
We shouldn’t have to do that I know. I just really want this truck to last. I’ll do the trans every 25K just cuz it’s easy now.
Been running great, smooth trans, no issues.
No tune. Burn TopTier 91-NoE cuz local station has it. Added a UPR catch-can at 1K miles & a hi-flow drop-in filter.
18” wheels, covered bed with 300lbs gear, AVE mpg so far with 14.8K mi shows 23.7 running around southwest CO, ave elevation 8000ft. I never use Sport mode, 90% in D & Tow even though I don’t tow (I just like the shifting better & helps with hilly terrain.)

Not to take OP’s post off topic with so much detail, but his rear diff issue just triggered me to share what I’ve done to hopefully prevent issues.

 

[pbethel]

The point is; Why did they even look at such a low mileage rear diff when the truck was in for power steering problem?
Either the least lucky person on this forum or we are not hearing about some very hard use and/or abuse.

 

[Muffin1]

The point is; Why did they even look at such a low mileage rear diff when the truck was in for power steering problem?
Either the least lucky person on this forum or we are not hearing about some very hard use and/or abuse.

Or unscrupulous Dealer service possibly padding a warranty claim... sorry i'm just a skeptical person when things seem odd, very odd.

 

[dtech]

Customer: My power steering isn’t working.

Dealer: Hmmm, we better check the rear end.

I’m skeptical OP. I don’t think even the worst dealer would do that. Something smells, here. Not a fishy small…more like a TuRD smell.

Maybe I just need my second morning coffee.

Doesn't checking a rear end usually involve a turd smell ? Been avoiding checking mine for that reason.

 

[Jason B]

Man, that's like going to the dentist and he tells you that you have colon cancer. Why were they even looking there?

 

[Ranger_Rocks]

Man, that's like going to the dentist and he tells you that you have colon cancer. Why were they even looking there?

 

[Dieseldean1]

Hi Morgan,

I have never in my 30 years at Ford Truck seen something like this. Please attach a copy of the Ford Dealer Repair printout of the repairs...very hard to imagine so much happening to one truck so soon... Ford quality is very concerning to me now.

Best,
Phil

I have a printout of a $427 bill to have Ford plug a scanner in and repeat to me what I told them when the vehicle was brought in.
They didn’t turn a wrench.
I got my keys back when I paid the bill.
I have a ‘20 Ranger, wife has a ‘17 Edge Sport. These will be the last Fords we buy.

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