Axle Assembly Problems of Ford F-150 - part 1

The contact owns a 2018 Ford F-150. While the contact’s son was driving approximately 20 mph, there was a screeching sound coming from the rear of the vehicle. Upon inspection, the contact discovered that the rear axle had fractured at the differential housing. The cause of the failure was not yet determined. The local dealer was not contacted. The manufacturer was notified of the failure, but no assistance was provided. The contact stated that the same failure had occurred twice on a previously owned 2013 Ford F-150. The failure mileage was 84,000.

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The contact owns a 2023 Ford F-150. The contact stated while driving at various speeds, the vehicle became very difficult to steer, and the rear end of the vehicle became unstable. The vehicle was taken to the local service center who removed the rear passenger’s side wheel and discovered that the rear axle bolt had sheared off. The vehicle was later driven to the local dealer. The cause of the failure was not yet been determined. The manufacturer was contacted but no assistance was offered. The failure mileage was 50,000.

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The contact owns a 2022 carry-on trailer hitched on a 2024 Ford f1-150. The contact stated that while taking a vehicle off of the trailer, the contact noticed that the tread on both the front and rear passenger's side tires on the trailer were excessively worn . The trailer was taken to an independent mechanic where it was diagnosed with improperly installed brackets that hold the axle onto the trailer. The trailer was repaired. The manufacturer was made aware of the failure. The trailer tire failure mileage was approximately 4,032.

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See attached letter.

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The contact owns a 2021 Ford F-150. The contact stated that while driving at an undisclosed speed, he heard an abnormal scraping sound coming from the rear driver's side of the vehicle. No warning lights were illuminated. The vehicle was taken to the dealer, who determined that the driver's and passenger's side rear axle bolts had sheared off. The vehicle was repaired, but the failure reoccurred. After investigating the failure, the contact related it to customer satisfaction program: 22b34, but the vehicle was not included. The manufacturer was notified of the failure but referred the contact to the NHTSA hotline for assistance. The failure mileage was 20,000.

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The contact owns a 2023 Ford F-150. The contact stated that upon inspection underneath the vehicle oil was found leaking from the rear passenger side axle. No warning lights were illuminated. The vehicle was taken to a local dealer where the vehicle was diagnosed and the contact was advised that the rear axle and seal were faulty and would need to be replaced. The vehicle was repaired. The contact referenced customer satisfaction program 22b34 as probable cause for the failure. The manufacturer was not notified of the failure. The approximate failure mileage was 48,000.

The contact owns a 2005 Ford f150. She stated that while driving 20 mph the vehicle fish tailed on an icy road. The back right tire hit a curb and caused the axle to snap and the tire to fall off of the vehicle. The vehicle was towed to the dealer and they replaced the axle and tire. The failure mileage was 58000. The current mileage was 60000.

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Brake problems several times now I have had to have calipers, rotors, etc replaced. Now my rear end seems to be slipping going around corners.

The contact owns a 1997 Ford f150. While driving 55 mph, the contact heard a loud pop and the vehicle pulled to the right. The vehicle was towed to the dealer and they stated that the axle tube was fractured. The repair shop replaced the cv axle and the axle tube. The current mileage was 136,000 and failure mileage was 135,000.

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Brakes, rear, leakage of lubricant from real axle through seals to contaminate rear brake rotors, calipers, etc. . This was found by technician at a Ford dealership while truck was in for an oil change. The entire rear end was replaced. It was a matter of time before the brakes would be inoperative. They could not tell if brake fluid may have caused the leak or a failure in the seals. I have all billing paperwork.

Driving in my back yard, testing new snow tires, speed aprox. 25 mph, hit 10" deep hole, broke axle, directly behind brake disc, rear wheel on the drivers side, pictures available. Had to replace axle.

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Drive train vibration thought the cab floor and steering wheel of vehicle. After numerous attempts to repair and 6 new tires, driveshaft and new clutch locking plates. New ring and pinion gear the problem still is there. The vibration progressively gets worse after long trips. Also there is a clunk in the drive line on acceleration and a severe to moderate shudder . Ford says that this is normal for the new body style trucks which is totally false. Ford seems to set their standard and customer satisfaction is set aside. The live with it attitude will not be tolerated. I am going through the bbb arbritration process and hopefully the arbritrator will see the history of this problem. Anyone with similar problems should e-mail me at glennlinokc@yahoo. Com.

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Rear axle whine at highway speed when accelerator is applied. Unrepaired two times by dealership. Third repair refused by me because dealership and Ford refused to replace the rear axle and wanted to keep my truck for an indefinate period of time to discover what the problem was without providing me a loaner/rental. A manditory recall should be required for all vehicles with this problem where the rear axle assembly is replaced, not just the ring and pinion. Under the current TSB's for this problem their is too much room for error! vehicle only has 5000 miles.

A high pitch noise coming from rear axle assembly and subsequent failure of the entire rear axle assembly. Dealer mechanics have found foreign components inside the rear differential assembly (a silicon sealer squeezed and wedged between the ring pinion gears and the input shaft) that may have caused the problem. They found the rear axle lubricant to be burnt and metal debris was also found inside the casing of the differential assembly. Vehicle failed at around 55,000 miles and 6 years of service. Rear axle have not been previously serviced by me or any other service facility before the above mentioned failure. The vehicle was purchased new and it has been in my possession ever since. To solve this issue and make the vehicle drivable again, a $2,500. 00 worth of repair (dealer recommended rebuild of the assembly) had to be performed. Ford is denying any claims that I have made in order to receive assistance. Old parts and the foreign component have been saved and are in my possession. I believe (with the support of the service rep. And the mechanic) that the poor assembly procedure at the factory and the foreign part found in the failed component to be cause of this problem.

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Rear axle broke, pulled me off the highway, witness behind me said it was as though the rear end jumped up. My truck was totaled, and because I hit a culvert that did even more damage to the underside, I'm not sure that can tell it was a mechanical failure. I took pictures of the tire marks in the wet grass and the right tire path was about two feet wide as if the tires were sideways, this was before the culvert was hit. The left side tire tracks were of normal width. I did not run off the road, I was pulled off the road. It seemed as though I still had control of the steering but the rear end went its own way. Was extremely lucky that no injuries/fatalities occurred. I at this point cannot replace my truck that I bought new and treated like a baby. The truck was taken in at least four times early by my husband, and they were to notify the Ford company. My husband passed away in December 2000, and being as I know nothing about the problem that occurred only when going over 45, I. E. , down the freeway as my husband often did, I assumed it was corrected, but so distraught that the mechanics of the truck was the last thing on my mind until the mechanical breakdown occurred. I think the Ford company should replace my defective vehicle with one of equal value, one owner, highway miles, and exceptional condition without any expense to me. I have a very high deductible, and will not be able to get a truck comparable with the money from the insurance company.

Contacts stated: he was in a double lane when the tire and axle broke off. Dealer said it was a factory defect. In 32 years he had never seen a break like that. The insurance company said it was their responsibility.

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3. 37 rear axle issues. Shudder at low speed turns / binding of lmtd slp disks. Order and inst spacer. "corrected" barely noticeable shudder but at about 800 miles, "whine" reappeared. Whine became louder over time. Dealer inspected the inside gear and pinion needed to be replace. Manufacturer out of stock. 1 month on order, new gear and pinion arrived. Dealer inst. At 800 to 1000 miles "whine" reappears. Dealer again inspects and orders 2nd gear and pinion. Rep made within a week of diag immediately noticed a low speed "rumming" noise. Returned to dealer. Ford field service tech relented to replacing the entire rear axle which is now on order. This diagnostic was the 7th in shop visit for the same problem.

15 days after purchase of vehicle, it was in to have the rear axle assembly replaced. One year later, it had the rear diff friction plates were replaced. 2 months later (right now) the rear end seals are leaking.

2004 screw lariat - vibration throughout whole vehicle at speeds between 45-60mph, only in o/d. I believe this is related to the contents of TSB 04-25-07 and TSB 04-25-08.

I purchased new Ford f150, the first time up to highway speeds the vehicle had a vibration between the speed of 55 and 65 mph.

Reported to dealer service dept. That my new 2004 Ford f150 fx4 truck had whine and clunking noise coming from rear axel/differential assembly at take off from stop and speeds between 45 and 55 mph. Dealer was instructed by Ford motor company engineering dept. Not to attempt repair. 1000 miles later the problem has got worse.

While driving at 45 mph, suddenly the right rear axle broke and snapped off. This resulted in the right rear tire flying off followed by the driver losing control of the truck and impacting a ditch . The driver sustained minor bruises. The engineer stated that the axle flew off on impact even though the tire flew off prior to impact.

I purchased a Ford f150 , thier was a vibriation in steering ,called sale's man and informed him of problem . We set up a service to balance tire's,this solved steering vibration, but caused vibration in rearend . Called service to have my truck inspected ,upon inspection and TSB a vibration dampner was installed along with rebuilding rearend. After receiving my truck back ,still had vibration between 40 and 50 mph took back to servjce they replaced rearend,driveshaft ,carrierbarring ,drove fine for two day's then vibration was back . Upon visiually inspecting the work , I noticed rearend was sitting about 1 inch farther to the right , I now am getting ready to take back to service to have work performed again. I have 5,161 mile's on my truck, rearend was first worked on before 3000 mile's and first oil change. Vibration persists.

The brakes began to shimmy and shutter and there was vibration from the rear when driving.

Test drove new F-150 super-crew-cab 4x2, at 60 mph experienced a terrilbe shimmy in steering wheel and bad vibration from left rear of truck. Returned truck to lot and test drove new F-150 super-crew-cab 4x4, experienced the same problem at 30 mph and 60 mph. Bought 4x4, salesman said the truck most likely needed wheel ballancing, or it was out of round. We made an appointment for two days later to address the shimmy/vibration problem. The mechanic had the truck on lift for twenty minutes. Result, dealer has to order a part for a service bulletin that requires a vibration dampening device to be installed. This is interesting, ther is a whole lot of new F-150 trucks at this dealership. I drove two and both had same problem. They (Ford), have a known service bulletin for this problem and yet as plentiful as this problem is on the lot they have to order the part, again for a know problem documentd by their bulletin that this part is required and they don't have it in stock to fix my truck or the other one I test drove on their lot or the next one and so-on and so-on. . . . . After reading all of these complaints there had better be a fix for this or I will surely deliver my $40,000 worth of inquiries and advertisements. Motor trend truck of the year. . . Or not!!!.

I have a 2004 F-150 (extended cab). While taking off, turning left or right- you will feel a vibration in the rear. This developed approx. 1 month after receiving the new truck. I have returned the vehicle to my service department, and the service manager felt the vibration as well. He ordered a whole new rear axle assembly, and this was replaced. He explained this problem was due to when turning- one wheel is moving faster than the other, which sometimes causes this vibration if it was not properly lubricated. I felt the vibration more when the vehicle was cold, and the axle was not warm. After the first repair, the new axle worked fine- but the problem has returned- approx. 1 month later. I only have 6500 miles on the truck, and this will be it's 3rd rear axle. If any one else is experiencing this, my vehicle's rear end was replaced, and will need to be repaired again.

2003 Ford F-150 super crew, howling/whining noise from rear differential during accelleration. Noise only occurres between the speed of 40mph and 60mph, most noticable at 50 mph. So far defect has not caused operational failure. Problem has been brought to attention of the Ford dealership who sold me the truck. First attempt to repair resulted in no work performed, noise considered acceptable by Ford specs. Second repair attempt (after writing to dealership) reslulted in service manager diagnosing a ring and pinion gear problem. They replaced the ring and pinion gear 3/30/2004. Problem reoccured after 4 weeks, additional attempt to repair resulted in originial conclusion that noise was acceptable per Ford specs. Inconsistent pattern of repair with problem still existing.

Rear axle whine noise at 45 to 50mph & 67 to 72 mph. Loud & getting louder. Ford dealers all over the area said Ford knows of noise but has no fix. Said they were told Ford would not spend money to fix because they were not making much as a company now. Two repars on rear end & still noisy, engineer had dealer put 125 wt grease in rear axle to try & quiet noise down. No good> lost fuel economy also. I need help getting repaired or getting a buy back from Ford.

Heard unusual noise coming from the rear-end of my 2003 Ford F-150 supercrew the noise starts at 90 mph. Is this an on going problem? please look into it.

Purchased new Ford harley pickup. Loud noise in rear, shop could not identify. Rear axle broke in curve and rear wheel on driver side was several yards from where truck finally ran off road and overturned. Total loss.

We own several Ford F-150 trucks. In the last 3 months we had four separate problems with the rear axles. One truck the axle broke and the wheel came completely off. Another truck the axle was destroyed and had to be replaced. The last truck is brand new with less than 2000 miles and experienced the same problem yesterday.

While driving 45 mph rear axle fell off, causing vehicle to flip over. Driver was ejected 40 feet away into a ditch. Due to the severe damage vehicle was totaled.

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Was driving down the road the steering wheel jerked to the right could not gain control back. There is one skid mark 35 feet long hit an electric pole when came to rest the back passenger tire had broke off at the axel. Dt.

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Axle seal on the left rear tire is leaking and causing brakes to fail, also not only on my truck but many other trucks locally the paint is cracking on both the driver and passenger doors and starting to rust near the bottom corner of the windows. They are only little spots but very costly to repair: upwards of $300- $500 dollars.

No summary. Dt.

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