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Old 10-26-2024, 10:34 AM   #1
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F250 rear differential failure

My 2023 F250’s rear differential developed a subtly whirring/rotational sound one month after our 8000 mile cross country, towing our 25W Arctic Fox, this past summer. Ford service found the spider gear worn, metal in fluid, and a not a clear answer on what bearing was involved. Vehicle and trailer under all gross weight ratings, confirmed with CAT scale weighing during trip. I now have an entirely new internal rear differential components. The failure unusual? Do I trust the dealer fix for future towing? The truck will be getting another workout next summer, and in the future God willing.
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Old 10-26-2024, 11:04 AM   #2
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Though not a common problem, there are a lot of parts in a differential, and some can go bad. We lost the front pinion bearing on our way back from Florida several years ago. Not something "mechanic in a can" can fix. I pulled the ring and pinion out and took it to a shop in Colorado Springs for a rebuild. Hardest part for me was getting the axles to release. You can do a full floater in your driveway with a floor jack.

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Old 10-26-2024, 11:22 AM   #3
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Quote:
Originally Posted by jagcyn View Post
My 2023 F250’s rear differential developed a subtly whirring/rotational sound one month after our 8000 mile cross country, towing our 25W Arctic Fox, this past summer. Ford service found the spider gear worn, metal in fluid, and a not a clear answer on what bearing was involved. Vehicle and trailer under all gross weight ratings, confirmed with CAT scale weighing during trip. I now have an entirely new internal rear differential components. The failure unusual? Do I trust the dealer fix for future towing? The truck will be getting another workout next summer, and in the future God willing.
It is pretty rare for a diff to go out on a relatively new truck like that without something abnormal causing it. Sure, a bearing might have been bad from new, or the diff simply maladjusted from the factory.

I'd be seriously investigating my tires, tire pressure, the loads I'd put in/on the truck before this happened and the fluid used in it, although I suspect it probably had the OEM fluid in it still.

1 or more tires with irregular diameter, different brands, or running in 4WD on dry pavement, or for hundreds of miles. Running at high speeds with too heavy a load can all cause issues.
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Old 10-26-2024, 11:32 AM   #4
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2000 F150 7700 model............1000 miles and rear end started making noise
Pinion bear failure

Dealer rebuilt the rear diff and I drove that truck until 2007 towing a 20' pontoon boat and a 1980 5th wheel.
I sold it to neighbor after I bought new 3500 for heavy towing
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Old 10-26-2024, 01:53 PM   #5
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It is pretty rare for a diff to go out on a relatively new truck like that without something abnormal causing it. Sure, a bearing might have been bad from new, or the diff simply maladjusted from the factory.

I'd be seriously investigating my tires, tire pressure, the loads I'd put in/on the truck before this happened and the fluid used in it, although I suspect it probably had the OEM fluid in it still.

1 or more tires with irregular diameter, different brands, or running in 4WD on dry pavement, or for hundreds of miles. Running at high speeds with too heavy a load can all cause issues.
All good thoughts. Four wheel drive has been properly used, tires original, inflated to 78 psi for trip and routinely checked. This past summer towing days were hot, July and August. The trip from New England our speeds were 60-65. The TT weighed in at 9200# and the truck at 8500#
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Old 10-26-2024, 03:13 PM   #6
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While everyone is just guessing, as to cause, no has asked if differential was given some break-in time before towing (500-1,000 miles)? Just another possible, but hopefully GTG, with no further issue.
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Old 10-26-2024, 03:36 PM   #7
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F250 differential

The truck didn’t tow until the 9000 mile mark. I’m being careful with the rebuilt, and not towing until I have more than 500 miles on it.
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Old 10-26-2024, 06:43 PM   #8
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as the others have said; pretty rare. load sounds light and I don't believe the break-in period matters. ...probably just a bad bearing, it happens. I wouldn't worry a bit about a rebuild; it should last as long as any other rear end as long as it's done properly.

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Old 10-27-2024, 07:58 AM   #9
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running in 4x4 is going to have no effect on a rear Diff.. Sometimes it just happens they get a bad bearing or other part on the build and it just fails. About an month before you go on your next long trip have your diff serviced and let them know that you had a failure and to look for shavings when they drain it, top it up with fresh and off you go.
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Old 10-28-2024, 07:14 AM   #10
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Failure that early in life is almost always a defective part. I wouldn't worry too much about the rebuild. I agree that to help calm your fears, have the diff serviced prior to your trip and check for any metal particles and that the fluid coming out is in good shape and has a normal smell.
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Old 10-28-2024, 03:39 PM   #11
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To the contrary- the 23-24 MY SuperDuties have been noted to have various axle issues. Early differential failure is not as uncommon as you think-a search of the various truck forums will provide a fair amount of reading
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Old 10-29-2024, 10:51 AM   #12
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To the contrary- the 23-24 MY SuperDuties have been noted to have various axle issues. Early differential failure is not as uncommon as you think-a search of the various truck forums will provide a fair amount of reading
I spend alot of time on various Super Duty forums as well and I'd suggest that any failures have been relatively rare.....certainly there have been some issues just like any component on any brand. earlier M275's had an issue with tube thickness for a short period in 2021 but that doesn't affect later trucks

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Old 11-08-2024, 09:18 AM   #13
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An update on the rear differential. After a break-in of 500+ miles, the rear end has a song to it when the powertrain is unloaded. I just returned from my local Ford dealer and the determination is that the specs. weren't set correctly during the rebuild and a complete rebuild of the rear differential is once again necessary. Rebuild is scheduled.
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Old 11-08-2024, 09:47 AM   #14
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An update on the rear differential. After a break-in of 500+ miles, the rear end has a song to it when the powertrain is unloaded. I just returned from my local Ford dealer and the determination is that the specs. weren't set correctly during the rebuild and a complete rebuild of the rear differential is once again necessary. Rebuild is scheduled.
Crap; I guess this falls under my "as long as it's done properly" statement..... Once it's finally done right, you should be good to go and have no ongoing concerns or problems.

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