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Discussion Starter · #1 ·
Just took 2018 3.0 diesel 4WD Lariat with slightly less than 35,000 miles on it, in to my local Ford dealer this morning for noise somewhere in front of truck. I took it in about 2 weeks ago for what I thought were 2 different noises, tech did find a hose rubbing, fixed that and said he thought that took care of it but if still heard anything to bring it back. After driving it I could still hear something that I didn't think was road noise, seemed to increase with vehicle speed. We went camping locally for a week so finally I got truck in this morning, explained what I thought was a noisy wheel bearing in front that seemed to be getting louder, though still not very loud. (Actually, I really was afraid they wouldn't find anything and I would have to wait for it to get worse or whatever.)
Anyway, after a while they came and told me the front differential was basically toast and were afraid entire differential would lock up! The way they explained it was the pinion gear (and associated gearing?) was worn out and entire differential would have to be rebuilt. They said could have been due to low level of differential oil though I have always taken this truck back to selling dealer for full servicing since buying it new.
They are to take front differential apart, see what needs to be done, said it needed rebuilding, take about a week, gave me a loaner.
My wife very upset and thinks we have a lemon. We've been through an awful lot with this truck (see earlier posts about getting stranded and having entire engine wiring harness replaced at about 5,000 miles) but I love it and have tried to stick it out, even against advice of many others.
I keep thinking that eventually all the bugs will be worked out but, man, these are some awfully big bugs on a new truck!
I'll post update on this latest problem when I hear from the dealer. To their credit, the local Ford dealer, Greenwood Ford, Bowling Green, Kentucky, has always been great to work with and I appreciate that. It just doesn't make these problems any easier to take.
 

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Good timing at 35K to be covered before your 3yr/36K Bumper-to-Bumper expired!

Ford manufactures nearly a million F150s a year, with a large percentage of them being 4WD models, and I haven't heard of this being a common issue. Given this is the first I've seen of this issue on these forums, I'm hoping this was a one-off due to an improper fill coming off the manufacturing line.

While getting all of your service at your selling dealer can be expensive, I do believe you get preferential treatment for issues like this, compared to some Average Joe off-the-street = glad to hear your dealer is taking care of you.

Please follow up after the repair and let us know how you made out.
 

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@Rdkeith99 - just had my scheduled 30K service performed yesterday. I was just in for an oil change a few months ago (haven't made 5K on last 2 oil changes) so it was the scheduled 30K items less engine oil/filter change.

Since it was nice out I spent a considerable amount of time outside of the service entrance, where I can peer into the service bays and luckily the diesel bay is the closest to the garage door, which is open all-of-the-time now with the nice weather.

I was surprised how much time my diesel tech spent under the engine with the truck up on the lift. Given I knew the oil/filter was NOT being changed, I'm pretty sure he was checking and filling the front differential.

I didn't remember if the front differential was part of the scheduled 30K tasks, but checking the FordPass app now, I can see it is (last item)
  • Replace engine air filter
  • Replace fuel filters, engine and frame-mounted
  • Inspect cooling system and hoses
  • Inspect automatic transmission fluid level (if equipped with underhood dipstick)
  • Refill diesel exhaust fluid tank
  • Check engine air filter restriction gauge, replace filter as required
  • Inspect brake pads/shoes/rotors/drums, brake lines and hoses, and parking brake system
  • Inspect and lubricate all non-sealed steering linkage, ball joints, suspension joints, half and drive-shafts & u-joints
  • Perform multi-point inspection
  • Rotate and inspect tires; check wheel end play and turning noise
  • Change engine oil and replace oil filter when indicated on vehicle message center or every 12 months, whichever occurs first
  • Inspect complete exhaust system and heat shields
  • MEMO: Diesel engine; Up to 7.0 quarts of oil (IOLM)
  • Fuel and water separator. Drain if necessary or if indicated by the information display
  • Inspect front axle lubricant level/condition
Given your failure was at 35K, I'm wondering why your dealer didn't catch this during 30K service/inspection...

For those owners coming up on the expiration of your 3yr/36K bumper-to-bumper warranty and handle their own service, might be prudent to let your Ford dealer do the complete 30K scheduled service to check the above items before your warranty expires...
 

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Discussion Starter · #5 ·
@Rdkeith99 - just had my scheduled 30K service performed yesterday. I was just in for an oil change a few months ago (haven't made 5K on last 2 oil changes) so it was the scheduled 30K items less engine oil/filter change.

Since it was nice out I spent a considerable amount of time outside of the service entrance, where I can peer into the service bays and luckily the diesel bay is the closest to the garage door, which is open all-of-the-time now with the nice weather.

I was surprised how much time my diesel tech spent under the engine with the truck up on the lift. Given I knew the oil/filter was NOT being changed, I'm pretty sure he was checking and filling the front differential.

I didn't remember if the front differential was part of the scheduled 30K tasks, but checking the FordPass app now, I can see it is (last item)
  • Replace engine air filter
  • Replace fuel filters, engine and frame-mounted
  • Inspect cooling system and hoses
  • Inspect automatic transmission fluid level (if equipped with underhood dipstick)
  • Refill diesel exhaust fluid tank
  • Check engine air filter restriction gauge, replace filter as required
  • Inspect brake pads/shoes/rotors/drums, brake lines and hoses, and parking brake system
  • Inspect and lubricate all non-sealed steering linkage, ball joints, suspension joints, half and drive-shafts & u-joints
  • Perform multi-point inspection
  • Rotate and inspect tires; check wheel end play and turning noise
  • Change engine oil and replace oil filter when indicated on vehicle message center or every 12 months, whichever occurs first
  • Inspect complete exhaust system and heat shields
  • MEMO: Diesel engine; Up to 7.0 quarts of oil (IOLM)
  • Fuel and water separator. Drain if necessary or if indicated by the information display
  • Inspect front axle lubricant level/condition
Given your failure was at 35K, I'm wondering why your dealer didn't catch this during 30K service/inspection...

For those owners coming up on the expiration of your 3yr/36K bumper-to-bumper warranty and handle their own service, might be prudent to let your Ford dealer do the complete 30K scheduled service to check the above items before your warranty expires...
Yeah, I have lots of questions for the dealer, like, why didn't they find/check the front differential fluid. Now I have to worry about the rest of the fluids (rear differential, transmission, transfer case). Tomorrow will be a week since I took it in so I'm trying to get in contact to see the status of the truck and repair. Thankfully I still have their loaner but I miss my truck! Well, life is full of woes.
 

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Discussion Starter · #6 ·
I hadn't heard from Ford dealer since last week so stopped by to "say hi" to my truck 🥲, see how the poor thing is getting along. Tech had ordered more(!) parts and parts were now in so they thought truck might be ready by tomorrow. I discussed lots of issues with the two service advisors (which I will discuss in a follow-up post) but my main advisor was flipping through page after page after page of parts they had ordered to install, he said looks like they replacing virtually everything in front differential.
They still not sure what caused failure. When they get repairs done I want to talk directly to the tech, see what his opinion is on what might have caused a massive failure at low mileage. Even the two service advisors were very surprised at that type of failure at such low mileage.
Now, after a major failure at 5,000 miles, now another at 35,000 miles, what next? The 2 service advisors told me that with this truck's history that I need to push Ford into offering me an extended warranty free (I want paperwork for this repair in front of me first), we'll see how that goes. I also want an estimate on the mega-bucks 😩 this repair (parts & labor) would have cost me if it hadn't been under warranty.
Anyway, I'll post more on this after repairs are done and I get the truck back 'cause this is far from over.
 

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Two weeks already! I wonder when this whole parts thing is going to smooth out. My local dealer has almost no new F150s.

Keep posting updates please, hoping you get her back soon.
 

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Discussion Starter · #8 ·
Two weeks already! I wonder when this whole parts thing is going to smooth out. My local dealer has almost no new F150s.

Keep posting updates please, hoping you get her back soon.
Yes, I can think of much more to post. Unfortunately, my posts have mostly related to some major problems. I'd just as soon read the forum and post about minor stuff, LOL! Maybe I'm too easy going, people keep saying I need to push for a replacement truck but I love the truck, just not these kind of problems.
As for supply issues, it seems that's a problem with most everything. It just goes to show how interconnected and fragile our supply system is.
 
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