Water in transfer case?

[GWM]

Any advise would be great.

I Was in an accident back in April. My 2022 Bronco Badlands sas has been in the shop ever since. The frame was twisted and then repaired. I received the vehicle back and realized the frame was still out of alignment, the rear differential was leaking, the transmission was shift wrong, and I had a popping noise in the front end.

All started after the wreck.

I brought it to Ford where it was given back to the frame shop. Once it was finished there, Ford fixed the transmission and rebuilt the differential. This had taken up to around the end of August to get that completed. They began to diagnose the popping noise in the front end and found that it was the transfer case causing it. Once they ordered a new one they drained the fluid and realized it was full of water.

No other water damage was observed. Only a single bolt on top of the transfer case was corroded. The Bronco has not seen water except for rain and the car wash. Ford is bringing in an engineer to take a look at it. Any suggestions on how this could have happened or has anyone heard of this before?
Appreciate any help thanks.

I forgot to mention the wreck did not involve water. I was towing a trailer with my 4wheeler when a guy coming head on crossed several lanes of traffic and hit the trailer .

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[PWillette]

Strange, no idea how the transfer would be full of water if you hadn't done any water fording. Did the dealer present a sample of the drained fluid?

 

[Funkdoobiest]

Ouch that seems like a lot of damage. With the bent frame, did insurance not offer the total it? Not sure why you would have water in in the t case.

 

[Brian_B]

If your Bronco has been in a shop since April, I'd be asking the shop. There are no good reasons it should be full of water, and you don't have any history of issues (I'm assuming) with the drivetrain prior to this; but, it's been outside of your control for quite some time now...

 

[GWM]

Strange, no idea how the transfer would be full of water if you hadn't done any water fording. Did the dealer present a sample of the drained fluid?

No they called me and advised. Have not seen it since I dropped it off to them.

Ouch that seems like a lot of damage. With the bent frame, did insurance not offer the total it? Not sure why you would have water in in the t case.

I sent State Farm a letter requesting it be totaled. Ford decided not to cover the rear differential, transmission and transfer case under the wreck. They advised it was warranty work. Had zero issues prior to the accident and have done no water fording.

 

[GWM]

If your Bronco has been in a shop since April, I'd be asking the shop. There are no good reasons it should be full of water, and you don't have any history of issues (I'm assuming) with the drivetrain prior to this; but, it's been outside of your control for quite some time now...

I agree, no issues prior.

 

[GWM]

No they called me and advised. Have not seen it since I dropped it off to them.


I sent State Farm a letter requesting it be totaled. Ford decided not to cover the rear differential, transmission and transfer case under the wreck. They advised it was warranty work. Had zero issues prior to the accident and have done no water fording.

warranty work until they found water in the transfer case. Still trying to decide on how they are going to handle it. Engineer comes in late next week.

 

[BadlandsA51]

If it was at the shop that long, it was sitting outside most of the time. I’m not sure where the TC vent is or what it looks like, but if it sat outside without the hood on it, could rain have gotten into the vent? I don’t know. And I don’t think I’ve seen a frame straightened in years, everything we get in the body shop at this dealership I work at that has frame damage gets a new frame, even if it’s just a damaged bumper mount flange. Sorry for all the hassle you’ve been through.

 

[JBlanco]

Has the area around the shop flooded within the time your car has been there?

 

[BadlandsA51]

If it was at the shop that long, it was sitting outside most of the time. I’m not sure where the TC vent is or what it looks like, but if it sat outside without the hood on it, could rain have gotten into the vent? I don’t know. And I don’t think I’ve seen a frame straightened in years, everything we get in the body shop at this dealership I work at that has frame damage gets a new frame, even if it’s just a damaged bumper mount flange. Sorry for all the hassle you’ve been through.

If it was heavily damaged, the Field Service Engineer will look at it very closely before he approves any warranty coverage, as he should. Warranty only covers defects in materials and workmanship, its not insurance against damage or neglect.

 

[Brian_B]

The more I think about this...

Why on earth would Ford volunteer Warranty service on something that:
a) was damaged in a wreck
b) had already been approved for salvage/total by insurance
c) but only specific items that aren't readily apparent would have been damaged in the wreck but not the entirety of the wreck

Half the time you can't get Ford/Dealers to look at valid, legitimate claims, or they try everything in their power to get out of coverage.

 

[GWM]

Has the area around the shop flooded within the time your car has been there?

Not that I am aware of. Only other thing I can think of is some how the a/c some how would get into the vent tube? Not sure how that would happen but only thing I can think of since there is corrosion on the top bolt of the transfer case.

The more I think about this...

Why on earth would Ford volunteer Warranty service on something that:
a) was damaged in a wreck
b) had already been approved for salvage/total by insurance
c) but only specific items that aren't readily apparent would have been damaged in the wreck but not the entirety of the wreck

Half the time you can't get Ford/Dealers to look at valid, legitimate claims, or they try everything in their power to get out of coverage.

I do agree not sure why Ford wanted to cover it under warranty. Insurance has not agreed to total it as of yet. I’m still debating with them in reference to that.

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