Front Differential Leak

[Bighorn Tremor]

I have a 2022 F-150 Tremor with the Torsen front differential. A few weeks ago, I pulled another F-150 out of a snow bank. Several days later, my garage smelled like gear lube and I noticed a puddle underneath the front differential case. Made an appointment to take it to the dealer. This didn't bother me all that much because A) It wasn't snowing, and B) My previous F-150 had constant issue with the front diff seal leaking. Dealer resealed the diff cover and sent me on my way. A few days later, it was puking oil in the garage again. Back to the dealer. This time they tell me the front diff is "cracked" and they need to replace it. Fortunately under warranty. Now I'm waiting for parts and we have 8" of new snow.....

 

[pittman]

I've heard of folks cracking the front differential housing. Were you pulling hard in reverse?

 

[Bighorn Tremor]

I was moving forward. If, and I mean, if, pulling out the other truck has anything to do with it, it was only because I gave him a hard yank on a snowy surface and the front Torsen activated under high torque.

But, the first trip to the dealer they didn't notice it, resealing the diff cover. My driving after that was all 2WD around town. Who knows?

I have a friend with an F-150 of similar vintage. He calls them "Covid Trucks" because they have little gremlins from sub-par parts and software.

I just hope the parts show up this week.

 

[SPOCI]

I was moving forward. If, and I mean, if, pulling out the other truck has anything to do with it, it was only because I gave him a hard yank on a snowy surface and the front Torsen activated under high torque.

But, the first trip to the dealer they didn't notice it, resealing the diff cover. My driving after that was all 2WD around town. Who knows?

I have a friend with an F-150 of similar vintage. He calls them "Covid Trucks" because they have little gremlins from sub-par parts and software.

I just hope the parts show up this week.

How many miles are on your truck? and how often do you use 4WD?

 

[Bighorn Tremor]

How many miles are on your truck? and how often do you use 4WD?

I am a couple hundred miles past 36,000. I use the 4WD quite a bit, most frequently in 4A, but also some serious off-road stuff. Much of my mileage has been longer trips or around town.

 

[SPOCI]

I am a couple hundred miles past 36,000. I use the 4WD quite a bit, most frequently in 4A, but also some serious off-road stuff. Much of my mileage has been longer trips or around town.

Interesting, truck should be able to handle that, its what its made for. I don't get off road enough!

 

[pittman]

There was a number of F150s cracking the aluminum housing on the front differentials a few years ago. It was chalked up to poor castings. Always seemed to be when the truck was hammered hard in reverse.

 

[Bighorn Tremor]

I didn't do anything to my truck that I haven't done in previous Fords, so my guess is a casting problem. I'm hoping the dealer took photos.

I have a friend who bought one of the first new Jeep Grand Cherokees. His wife buried it in the snowy road to their house. Trying to get it out, the drivetrain locked up. After being towed to the dealer, they found that the rear diff casting had broken completely apart. The rear end was completely rebuilt on that vehicle. Amusingly, he was the guy whose F-150 I had to pull out of the snowbank.

 

[Bighorn Tremor]

UPDATE: I finally got the front differential replaced on my Tremor last week. It took several weeks for the dealer to get the parts. The first order got "lost" and they had to reorder. Then after the parts arrived, they couldn't get the truck in for repair for a week. And, then, rather than the "3/4 of a day" they originally promised, it took them a full two days to replace and repair.

I never found out their thoughts on why the front differential cracked. My guess would be a casting issue, especially since it was replaced under warranty without any question.

From what I can tell, everything works again like it is supposed to. Pretty certain the front Torsen was doing its thing in some slippery conditions over the weekend. We got 6" of new snow overnight, so perhaps I'll see what today brings.