Humming vibration = rebuilt front differential

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mtn5

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2016 EL Limited, 58,000 miles. Last Dec (2020) I started hearing a humming vibration and felt it in the gas pedal and in the steering wheel. Happened generally on low-speed turns 5-25 mph and only happened intermittently. Some days nothing, other days all the time. Truck was in 2H.

I bought this used last spring with about 52K miles. I decided to spend the $150 to have the local dealer (same I bought it from) take a look at it thinking it would be wasted but I'd give it a shot. To my surprise dealer called to tell me they pinpointed the sound to the front differential and there was metal shavings/pieces in the fluid. The pinion gear was failing.

They ended up keeping the truck for 2 weeks - rebuilt the differential and evidently had trouble finding the right shims, but eventually did. Fortunately this happened while still under the 60K warranty. Total cost was ~$2200. I have a 1 year warranty on the fix.

This is mostly an FYI for someone with similar symptoms.

Anyone with similar experience? I figure the person who had it before me misused the 4wd system, like 4H on pavement or something(?) Makes me think twice that something like this would fail at 58k miles and makes me wonder if the rebuild will last.... I might start looking at an extended warranty.
It also seems like I can feel and hear the difference, almost like there is no oil in the differential, or the gears are just really tight. But, I don't know how a new one should feel so maybe everything is right.
 

arbetrader

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Mine failed too on my 2015. Didn't know it until right after I bought it because I thought it was wheel bearings that had to be replaced. While they needed replacement, the front end was still very noisy. Whole front diff was shot. All bearings were very damaged including carrier bearings.

Thankfully my friend is a Master Ford tech and he rebuilt it for me for cheap.... He was surprised it went out with only 110k miles on it
 
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