2020 rear axel previously replaced and now a destroyed differential

[Nashcp21]

In January 2024 at 61,000 the dealer replaced rear axel because seals were leaking. Just out of warranty, it cost me about $1,400 USD.

Well, after only 6 months, 8,000 miles later I returned from a weekend trip with oil leaking out of the differential. The tailgate was covered with it. Dealer says "differential needs overhauled due to pinion seal leak got low and burnt up bearings” – looking at $2,7000 & 2-3 weeks waiting on back-ordered parts!

So my thinking is that they had to take apart the differential to replace the rear axel in January? Shouldn’t they have replaced the seals on the differential? What are the chances they botched the job, and caused this to happen? I found out by chance that tech who did the pervious repair doesn’t work there anymore. Would appreciate thoughts about this.

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[Stevedbvik1]

In January 2024 at 61,000 the dealer replaced rear axel because seals were leaking. Just out of warranty, it cost me about $1,400 USD.

Well, after only 6 months, 8,000 miles later I returned from a weekend trip with oil leaking out of the differential. The tailgate was covered with it. Dealer says "differential needs overhauled due to pinion seal leak got low and burnt up bearings” – looking at $2,7000 & 2-3 weeks waiting on back-ordered parts!

So my thinking is that they had to take apart the differential to replace the rear axel in January? Shouldn’t they have replaced the seals on the differential? What are the chances they botched the job, and caused this to happen? I found out by chance that tech who did the pervious repair doesn’t work there anymore. Would appreciate thoughts about this.

Pretty sure that the axle shafts can be replaced without touching the differential. Dealer would have checked fluid level after reassembly as part of the repair.

 

[ctechbob]

Personally, if I were out of warranty I'd look for a used unit from a wrecked truck.

Swap your brake hardware over and change the fluid and roll on.

 

[Stevedbvik1]

Personally, if I were out of warranty I'd look for a used unit from a wrecked truck.

Swap your brake hardware over and change the fluid and roll on.

Wow $580 for a locking rear axle with 24K on it ?

 

[ctechbob]

Guess I should have linked the site:

https://www.car-part.com/

Keep in mind, you are dealing with salvage places directly, so be prepared for a lot of unreturned emails, and other BS you need to jump through, but if you have the time to jump through the hoops, it can be worth it, especially if you find one locally for a good price.

IMO, axles are a lot of black magic when it comes to setup. I know it really isn't that difficult, but a lot of times, the best unit is a factory assembled one. Once you open them up and start replacing parts, they're never the same again.

 

[Jason B]

In January 2024 at 61,000 the dealer replaced rear axel because seals were leaking. Just out of warranty, it cost me about $1,400 USD.

Well, after only 6 months, 8,000 miles later I returned from a weekend trip with oil leaking out of the differential. The tailgate was covered with it. Dealer says "differential needs overhauled due to pinion seal leak got low and burnt up bearings” – looking at $2,7000 & 2-3 weeks waiting on back-ordered parts!

So my thinking is that they had to take apart the differential to replace the rear axel in January? Shouldn’t they have replaced the seals on the differential? What are the chances they botched the job, and caused this to happen? I found out by chance that tech who did the pervious repair doesn’t work there anymore. Would appreciate thoughts about this.

Seems like they replaced only seals and maybe bearings on the first repair of $1400. Since you are out of warranty, I'd look for a used one, or try another shop, they will be cheaper and faster than Ford.

 

[Rp930]

First you need to know exactly what was done the first time.

 

[Stevedbvik1]

Another possibility is that because the axle seals were leaking the fluid level was low and may have done some damage to the pinion bearings but not enough to detect at the time of repair. Dealer replaced axles/seals and topped off the fluid but the damage had already started and finally failed causing the pinion seal to leak leading to your current situation. Again knowing what they did on the first repair would help. Can you post a copy of the repair order from the axle seal repair?

 

[Nashcp21]

Another possibility is that because the axle seals were leaking the fluid level was low and may have done some damage to the pinion bearings but not enough to detect at the time of repair. Dealer replaced axles/seals and topped off the fluid but the damage had already started and finally failed causing the pinion seal to leak leading to your current situation. Again knowing what they did on the first repair would help. Can you post a copy of the repair order from the axle seal repair?

Here is the what I've got...

 

[Stevedbvik1]

Ok. That sheds a lot of light on your situation. First of all they replaced both axle shafts so the differential was not touched. Second, They had to add two quarts of differential fluid which is quite a bit. Which points to my speculation of possible bearing damage. Third, the highlighted comment about a noise being detected after axle replacement and asking you to monitor it also points to my speculation. Did the noise go away? Did you ever get back to them about it?

 

[Nashcp21]

Ok. That sheds a lot of light on your situation. First of all they replaced both axle shafts so the differential was not touched. Second, They had to add two quarts of differential fluid which is quite a bit. Which points to my speculation of possible bearing damage. Third, the highlighted comment about a noise being detected after axle replacement and asking you to monitor it also points to my speculation. Did the noise go away? Did you ever get back to them about it?

Yeah so the noise that I was asking about back then was the differential whine. I was ignorant of it back then, but it's the exact same behavior and sound as with the current issues.

In January, I complained about the drivetrain making noise as I couldn't pinpoint it. After they diagnosed and did the axels, I was told they didn't find anything wrong and the sounds that the vehicle was making were 'normal'. When I got the it back, the sound was still present but not as loud, (perhaps due to the fluid being topped off?)

If I had more knowledge at the time, I would have made that connection. They didn't discuss adding so much fluid with me either

 

[Stevedbvik1]

Yeah so the noise that I was asking about back then was the differential whine. I was ignorant of it back then, but it's the exact same behavior and sound as with the current issues.

In January, I complained about the drivetrain making noise as I couldn't pinpoint it. After they diagnosed and did the axels, I was told they didn't find anything wrong and the sounds that the vehicle was making were 'normal'. When I got the it back, the sound was still present but not as loud, (perhaps due to the fluid being topped off?)

If I had more knowledge at the time, I would have made that connection. They didn't discuss adding so much fluid with me either

Unfortunately they noted in writing the noise after the axle repair and asked you to monitor it so that pretty much relieves them of any responsibility. Whether they verbally communicated it to you is moot because it’s in writing on the repair order as was the quantity of differential fluid. Sorry to be a downer but it doesn’t seem like it’s their problem. They may be guilty of poor communication but that becomes a he said she said when it’s backed up in writing. Hope you find a inexpensive remedy.

 

[Nashcp21]

Unfortunately they noted in writing the noise after the axle repair and asked you to monitor it so that pretty much relieves them of any responsibility. Whether they verbally communicated it to you is moot because it’s in writing on the repair order as was the quantity of differential fluid. Sorry to be a downer but it doesn’t seem like it’s their problem. They may be guilty of poor communication but that becomes a he said she said when it’s backed up in writing. Hope you find a inexpensive remedy.

Yeah I agree, it seems like I am stuck paying for the repairs myself. In any case, thanks for your time and consideration.

 

[Stevedbvik1]

Yeah I agree, it seems like I am stuck paying for the repairs myself. In any case, thanks for your time and consideration.

No problem, glad to “help”

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