Driver Side Front Axel leaking grease and grinding

[11Bronco1776]

Unfortunately I get to post my experience in this thread, fortunately we have this thread to communicate.

Took my 4dr Badlands in for a rust inhibitor undercoating and I found a large amount of grease all over front driver side tire and axel area. Also had a slight grinding sound that I didn't think much of prior to the discpvery but has since grown worse.

Ford dealerships backed up for weeks out here in Utah so it took forever to get it in to get checked out. Finally did and today they confirmed the grease issue and stated there must be a small hole in my cv boot. They have to order and replace entire driver side axel per the mechanic. They weren't able to replicate the grinding but my video is proof enough it's there and I am sure related.

No clue how there is a torn/hole in the boot. So far only Highway and City driving no off roading yet.

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[PWillette]

Dam, that sucks man. No doubt the grinding is related, she running dry more or less. Guessing the boot was damaged during installation. Glad your dealer is on board for a correct repair.

 

[MDH Bronco]

When I picked my Bronco up on December when the mechanic was doing the PDI they found a slight tear in the driver's side cv-boot.
(Great catch) they ordered a hole new shaft and boot assembly and installed it they were awesome.

 

[FootPain]

I also have a slight cut on my CV boot. Less than an inch. Caught it early and it's got a temporary fix until I can get into my dealer.

 

[MDH Bronco]

Maybe they need to look at there assembly process

 

[BroncoWTFAN]

Maybe they need to look at there assembly process

How about they look at the entire process, not good.

 

[11Bronco1776]

Just got my bronco fixed and picked up today, had to order part and wait on timing to get into dealer. Drove it in meantime. New driver side axel installed but still hearing a strange noise I need to diagnose. It's intermittent. Here it is sitting at idle still in dealer lot. Ideas? Seems my crawler gear isn't as torque as before not sure if related. Hard to tell with nothing to compare it with.

 

[da_jokker]

I was going to ask if you saw the other post about no 4x4 where a guy's axle wasn't fully seated from the factory, was leaking and ended up grinding a bunch of splines off.

That looks like yours is already been fixed, except for that terrible noise which I have no idea...sorry.

 

[rrknapp]

I was going to ask if you saw the other post about no 4x4 where a guy's axle wasn't fully seated from the factory, was leaking and ended up grinding a bunch of splines off.

That looks like yours is already been fixed, except for that terrible noise which I have no idea...sorry.

Yes, that is what happed to us. They Local dealer denied claim because of 35" tires and the 2" spacer lift from Rough Country. I'm going to do a post on what I found. In the meantime this is what it looks like.

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