Front Differential on a 2023 Badlands....again

[Valhalla]

After going to Coalmont OHV area this past weekend I noticed what sounded like grit in my brakes while in 4x4. It slightly acted like it did not want to come out of 4x4 once back to pavement. ( that's what happened the first time) I was under it cleaning the mud off after the trip and found that the front driveshaft was contacting the sway bar. I dropped it at the dealer yesterday. They already found the issue. They said two bolts are sheared off of the differential and they are unsure if it is from their install or the front differential. They are replacing the front diff again. Here is a link to my first issue. And a picture of where the shaft ground off part of the shaft flange from contacting the sway bar.
https://www.bronco6g.com/forum/thre...st-post-for-short-version.63675/#post-1757297

Sponsored

 

[Mdozier]

Ouch. With the modifications you’ve made did they push back either time on warranty coverage? Curious, mine should be here next month.

 

[Silver-Bolt]

At least the dealer is being cool about it.

 

[Valhalla]

The first repair was prior to mods.
They seem cool about it.

 

[Valhalla]

That being said, I run stock tires on highway, unless it's a local off-road spot then it may see the swampers on road. I trailer for farther away. I run it aired down to where tire height is actually around a 34.5...

 

[Valhalla]

UGGGGHHHH now we are having to wait for the sway bar to come in to replace that because of the messaging the driveshaft gave it....

 

[Valhalla]

The driveshaft ground a place in the sway bar... no ETA from Ford on a replacement...I planned on a trip in June

 

[Snacktime]

Post pictures of the internal damage when you can? I am curious how hard these clam shell diffs are to set up the pattern.

 

[V1Rotate]

The driveshaft ground a place in the sway bar... no ETA from Ford on a replacement...I planned on a trip in June

Just run it without the anti sway bar

 

[Valhalla]

I'm thinking about having them put it together with it on. I don't think it will cause it to fail.

 

[Valhalla]

Marshall Mize is being an awesome help. Since the replacement sway bar disconnect won't arrive till July they are putting it back together this one till it arrives!

 

[Wasane]

What bolts ripped out of where? Do you have any additional photos?

 

[Valhalla]

I never saw what sheared as the dealer replaced it under warranty.

 

[Wasane]

I never saw what sheared as the dealer replaced it under warranty.

I am dealing right now with the same thing. My driveshaft ground through itself on the oil cooler and sway bar. But difference is all my bolts are fine. Its my frame diff mount its self that broke off. I am getting my waranty denied. Is it possible for you to find the paper they gave you after waranty work was completed. It should have everything explained on it. And also did you have front differential replaced before this break accured?

 

[Valhalla]

I am dealing right now with the same thing. My driveshaft ground through itself on the oil cooler and sway bar. But difference is all my bolts are fine. Its my frame diff mount its self that broke off. I am getting my waranty denied. Is it possible for you to find the paper they gave you after waranty work was completed. It should have everything explained on it. And also did you have front differential replaced before this break accured?

Yes, my first differential was bad from Spicer. So my dealer had r&red the differential. I assume there were non reusable bolts that sheared. This was about a year ago. I am out of town. Send me a PM on May 5th and I will see if I can put my hands on that work order.

Sponsored