Differential Unit Problems of Ford F-150 - part 2

I started to get a vibration in the rear of the truck at 45 mph. I had just replaced the tires not long before and thought they might be out of balance. They are not. They have been checked many multiple times and rotated. The problem still exist. The dealer doesn't know what the problem is and claims it's not the differential or rear axle. I have replaced the bearings, seals, gear lube and rear shocks. Now there is a knocking sound coming from the rear end. It is a 4x2 and has not been driven hard. The vibration, which was annoying at first, has progressively gotten worse. The whole bed of the truck shakes when I hit 45 till about 55. ## VIN passed ## Ford f150 2004 ##.

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The contact owns a 2006 Ford F-150 equipped with 4 wheel drive. The contact stated that the rear differiential was not functioning correctly and the rear wheels felt as if they were sliding from the rear of the vehicle. Also, the rear of the vehicle seemed to have no traction. He had the rear differential replaced. The contacts major concern was that one could lose control of the entire vehicle if the rear functioned in this manner. The failure mileage was approximately 38,000. The current mileage was approximately 40,000.

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Transmission failure, driving to work, transmission shift into neutral , again and again, lost of power in traffic while driving ,all fluids were normal, will not shift into 3rd gear, slips into neutral at 34 mph, 80,176 miles on od. I drove to Ford dealer in 2nd gear, $450. 00 just to look at, 3- rings +valve body need replacing, total of $2,468. 00 cost of repair. Safety issue == loosing all drive power in traffic, this should have been a recall after seeing all the complaints on this website this is my second big repair with drive train. At 60,000 mile a had to replace the rear differential at $1,600. 00+ , I do not tow anything and do not use the truck for work, 4. 6l , 2-wheel drive.

2004 Ford F-150 4. 6l v8 regular pickup truck, 39,000 miles on odometer - driving 50 mph and the truck starts vibrating horribly like driving over a washboard road. Nothing will cause the vibration to stop, even throwing the vehicle into neutral. Must stop completely, and sometimes put the transmission into reverse for a moment, then put it back into forward drive, to make the problem go away. This happens periodically, about once every couple of weeks. Search on google reveals hundreds of others complaining of the exact same thing with their 2004 F-150 trucks. Most claim it is an expensive differential problem, and caused by some tooling error at the manufacturing plant. Ford has not initiated a recall, and this is an expensive and dangerous problem. The problem just happened again today, September 17, 2010, and I now have 43,000 miles on my truck. It's used for getting groceries. No heavy use, ever. Also, the dozens of complaints from other 2004 Ford F-150 owners said their trucks only had 35,000 to 45,000 miles on them when the problem surfaced.

I purchased a 1998 Ford F-150 in 2000 from carmax in arlington, TX. I have had no major problems until Nov. 7th 2008. I was driving and approached a traffic signal. I attempted to depress my brakes when the vehicle locked up and spun sideways at the intersection. When I exited the vehicle I found that my driverside rear differential had broken lose and the rear differential clamp had broken off allowing the entire driverside differential to fly off of the vehicle. % minutes earlier I was on the freeway. If this would of happened on the freeway, I would not be here today.

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Rear differential was chattering/shuddering on slow take off turns. Problem is well known and documented by customer complaints. Issue faulty clutch pack in the positraction rear. Vehicle had 39,000 miles so out of warranty. Both dealer and Ford gave some on repair. About $400 toward $900 repair. Helps some but still can't get past why a mechanical failure on a part that should last 100,000 miles.

Spider gears in differential blew out for 2nd time on this truck which is a 2002 F-150 4x4 with a 3. 55 diff. The first time was at around 45k mi. And this time at 83. 5k miles. This truck was never overloaded and never pulled a trailer. Must be something wrong with Ford rear. After this repair,I am done with Ford!!.

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The contact owns a 2004 Ford F-150. The contact stated that the differential pressure sensor (dps) has melted and burned up on her engine. While driving 50 mph uphill, the vehicle began losing speed, making a hissing noise, and the check engine light illuminated. The vehicle restarted and she was able to drive home. She stated that the vehicle was driving normally when driving straight, but the engine failed when attempting to drive uphill. The current and failure mileages were 86,226.

Differential rear end factory defect.

See all problems of the 2003 Ford F-150 🔎.

In November 2002, I purchased a 2002 Ford F-150 extended cab, which was made in canada 09/01. After the break-in period I noticed that at speeds of 80-85 mph the vehicle would whine , but I assumed that was normal because after 85 mph the whine went away. At about 89,000 miles and the end of the warranty, at 35-50 mph the vehicle would have loud roaring/whining noise from the rear end. Took vehicle to dealer for repairs on 10 January 2007,. The dealer replaced the pinion gear and assembly at a cost of 1501. 00 , and the dealer said it was fixed. I drove the vehicle less than 1,500 miles after the repair was made, the vehicle started doing the same thing again at speeds 40-50 mph, but with an added twist this time, the truck would whine even when I accelerate. I put the truck back in the shop for the same problem again on 01/23/2007. The truck has a 3. 55 rear end.

Grinding in rear axle assembly, differential needs rebuild,57k. . .

At about 75k miles, a very faint whine was coming from the back end of the vehicle, mainly audible with acceleration and at speeds of about 35 mph. It slowly progressed, we took it to a local Ford dealership and was told that this is happening with many Ford 150's with this year, it was a defect in the parts (the material it was made with). We were told to continue to drive it until noise was too loud. At 92k miles, it was a pretty loud whine at all speeds except about 70 mph, and then progressed to a grinding noise. I just took it into the dealership, they said the rear differential, pinion and carriage gears were "torn up". They found a replacement and total cost is $1800. At this point Ford is not fixing part, since there is no extended warranty, but this is not a part that should be going out at 90k miles either, and with the dealership saying this is happening often and there was a defect in the part, Ford should be recalling this, or at the very least paying for the fix when it starts to go bad.

: the contact stated that an independent mechanic determined while servicing the vehicle that there was a premature failure in the pinion bearings and the carrier bearings from the rear end of the vehicle. Updated 7/13/2006 - the differential unit started making noise. The vehicle was taken to an independent repair facility and told that the carrier bearing and pinion bearing and the races for both were pitted and had black streaks on them.

See all problems of the 2001 Ford F-150 🔎.

2002 Ford f150.

The brakes began to shimmy and shutter and there was vibration from the rear when driving. The problem started three months after the vehicle was purchased and recurred every three, four or five months. Four repairs did not eliminate the problem so a fifth repair was required on Jan 25, 2006 with 32040 miles. During the five repair the rotors were resurfaced twice and replaced three times. The brake pads were replaced three times and the front brake calipers were replaced once.

The consumer stated that the rear differential on his 2001 Ford f150 rusted. The consumer was having the vehicle fixed. The vehicle was regularly maintained. The dealership/manufacturer were not notified. The consumer said that the rusting starting about a year ago. The consumer stated the rear differential cover has rusted through and was leaking fluid. The rust was not isolated to just one spot.

The contact owns a 2002 Ford f150. The rear end differential made a whining noise. They told him that it will not hurt the vehicle but it was not normal since the June 16,2005 contact was trying to get vehicle fixed. They replaced the rack and pinion twice, but problem recurred. The manufacturer told contact that they could not fix the vehicle. Technician at dealership said he owned the same vehicle and it was doing the same thing. The dealerships laughed when contact brought the vehicle to be fixed. At 40-45 mph contact could hear the noise ,and if when pulling ta load the noise got worse. The dealership tried to fix this problem, but Ford kept sending wrong parts that were not correcting the problem. Contact has have an extended warranty on vehicle.

My 2004 Ford f150 vibrates. The dealer has mad e four attempts at repairs with no success. Currently, the vehicle will suddenly start to vibrate severely at freeway speeds, and the only way to stop the vibrations is to slow down to 20 to 25 mph. Slowing down this much on the freeway is unsafe it could cause an accident. When this severe vibration starts, it's as if something is about to fail in the driveline. As it is now, I have no confidence in this vehicle, and am reluctant to drive it. Vehicle was purchased new on 7-10-04, and now has 6770 miles.

Rear end shudders or slips when accelerating from stop and turning. . . There is also a whining sound coming from the rear end. . . From reading nhsta complaints this seems to be quite a large problem with this truck. . . Seems like Ford would step up and fix whatever it is. . . . Worst truck I ever bought.

I have a 2003 Ford f150 my 4wheeldrive stopped working , but the dash indicator said it was ingaged. This makes for a very unsafe operating condition. Because you do not drive the vehicle the same if the 4x4 is working. I brought it to the local Ford dealer and they repaired it . This apparently was a common problem. The part# f75z*3n139 which cost$133. 98 and the labor was $302. 00. This part is very cheaply made and will probably break again. The tech told me there is no way to prevent this from happening again. This part is a safety hazard. I hope that you investigate this matter. I have looked on Ford links and websites and have seen numerous comments of this problem. Please if you can help me, it would be appriciated. I kept the old parts, the material they use on the fork won`t hold up to the conditions in the front differential.

The 2004 f150 and I assume expeditions had undersized front brake rotors and calipers and were outlined in a service tech bulletin for the purpose of diagnosing the front end shaking/shimming during braking. This is my opinion should have fallen under a mandatory recall due to the serious nature of poor engineering. No recall and out of pocket $$$. The same holds true for the rear differential which in my case has been replaced (3) times and again Ford published a tech bulletin outlining the fact that the '04 rear differential housing was subject to faulty machining causing rapid wear on ring/pinion and bearings. I believe these two defects should have been addressed due to the fact that failure of either component could result in a serious accidents. I truly believe Ford tried to cover up/white wash these defects. I still have this '04 and still have issues with the brakes and rear differential not to mention a host of other issues that have plagued this particular year model. I look forward to hearing from someone and would like to know the extent of Fords involvement and any accidents involving '04f150's. Best regadrs.

The contact owns a 2004 Ford F-150. The contact stated that the vehicle began to violently shake while driving 35 mph. The vehicle was maneuvered to the shoulder and the contact noticed that the rear differential failed. The dealer made three attempts to duplicate the failure. The manufacturer was not made aware of the failure. No repairs were performed. The failure mileage was 4,000 and the current mileage was 62,000.

I purchased a new 2004 Ford F-150 supercrew. The rear differential made a "whining" sound between 45-50 miles per hour from the day I purchased the truck. My truck now has 7000 miles on it and the whine has become extremely noisy and now makes the whine from 45 mph to 70mph and above. My Ford dealer will not make any repairs on the truck becasue they are told that Ford motor company is "investigating the problem" . Ford motor company has been investigating this "problem" since 07-04. It is not 01-05 with no progress to this problem and it has become so severe that I get headaches just from commuting every day listening to the constant "whine" sound. There needs to be a recall or something to make Ford fix his problem as I can't even sell my truck as no one would even consider owning it.

Continuing problem with the truck, there is a vibration from the driveline. It has been in and out of service since 11/25/04 until present for the same issues. Ford orginally did not know the problem, and went down the TSB list replacing different parts such as transmission mounts and differential bearings until the last service on 1/27/05 finally fixed the problem by replacing the ring and pinion in the rear differential. However, on 4/15/05 I noticed a vibration and grinding noise from the rear end when turning from a stopped position. Vehicle wikk be back in service on 4/25/05.

As noted by another complaint: howling noise in rear differential. Rear differential replaced once. Noise continues. I called Ford motor company and they told me there was a design flaw that only affects certain vehicles but they are working on the problem. I asked. . . When could I expect it to be solved. The answer was. . . It might never be solved. They replaced some gears in the differential, but the problem has started again. They refuse to put in a new differential saying that it would be "cost prohibitive".

The differential has disintegrated inside. This was caused by a bearing which came apart and caused everything inside to shift about an inch towards the drivers side. How dangerous is that? ultimately, the housing, ring gears and other gears inside were damaged beyond repair. It started with a slight hum at 45 mph and within two weeks completely broke so that the driveline turns within the housing while the wheels stay put. I use my truck only for street transportation and have taken impeccable care of it. The truck has 102,000 miles on it. Only two months ago, I had the fluid changed everywhere including the rear end. I have put a rebuilt rear end resulting in $2600 out of my pocket. Thanks mr. Ford for that!.

Noise in rear end abount 60 to 70 miles a hour. Whinning noise.

2004 f150 with the 4. 6 liter v8 engine and limited slip differential. When the truck is running @ 2100 rpm at highway speeds something in the rear end makes a strange "warbling" type of high pitched noise. It only does it @ 2100 rpm. Local dealer tried to tell me it was exzhaust resonance. They replaced my exhaust system and the problem persists. They are investigating to determine true cause.

Takata purchase our 2004 Ford f150 4x2 supercrew from kings Ford. When going to tenn. Pull off to get gas and when leaving the gas station making left hand turn real wheel lock up had to back up to unlock the rear wheel, called kings Ford and was told not to make sharp turns. Returned home with the rear end making banging noises, king Ford repaired on Aug 24 2004 replace the traction lock clutch pack part#4947 2151 miles. After the repair we notice a whining sound coming from the rear end was told to bring the truck back, droped the truck off on sept 30,2004 and to pick it back up on oct 2, was told by service rep no work was done. Caller service rep the flowing Monday and was told Ford would not pay for the fix because engineering is currently investigation this condition and for us to call every month. Called Ford many times finely was told to take our truck to Lincoln Mercury garage in fairfield, ohio had a person that would rebuild the rear axle with 4205a differential carrier. Assemble, Ford did take care of this. After leaving the garage notice a whine in the rear turn around went back to the garage and was told they may have the parts to tight and will need to loosen then up. This has been going on for the last 15 years with still no fix we have now 95800 miles and with another fix for $3000. 00.

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

Ford f150 ex cab 2 wheel drive at 1400 miles loud noise from rear end during turns or acceleration. Dealer replaced parts in differential. Since dealer fix, loud "humming" noise from rear end over 35 mph. Vibration from rear end while going 40 mph+.

Rear end differentials make a loud noise when driving at 50+ mph.

At speeds of 52, 54 mph the rear end makes a "wining noise" like the pinion gear is bad. Took truck in for serivce to dealership and they said Ford says the noise is normal engnieering. I don't agree and am very annoid with the dealer and Ford.

Tires replaced at less than1,000 miles. Rear end replaced at less than 5,000 miles steering whille vibration at high speeds reported from day one. Tires rebalanced and front end checked more than 3 times and still have vibration at high speeds. Rear electric slideing glass motor bad at 6,000 miles.

Howling noise in rear differential. Rear differential replaced twice. Noise continues. Ford now refuses to repair rear differential because of complete overhaul twice. Ford now says noise is "characteristic" of this vehicle. This is not true as I have driven other identical vehicles without the noise. Noise goes away after repairs are made for about 6000 miles.