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10-26-2024, 10:34 AM
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#1
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Junior Member
Join Date: Jun 2011
Posts: 7
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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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10-26-2024, 11:04 AM
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#2
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Senior Member
Fleetwood Owners Club Workhorse Chassis Owner
Join Date: Jun 2016
Location: On the continental divide
Posts: 3,109
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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.
Mike in Colorado
__________________
2004 Fleetwood Pace Arrow 37c, 8.1 gasser, (Jezebel) Ultra RV ECM / TCM, plugs wires, and rear track bar, PPE deep Tx pan w/ temp gage, Bilstein's, Sailun's & Sumo's all round, pushed by a 2002 Grand Caravan, on a Master Tow Dolly OR a WR-250 on a rail.
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10-26-2024, 11:22 AM
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#3
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Senior Member
Join Date: Mar 2019
Posts: 3,061
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Quote:
Originally Posted by jagcyn
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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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.
__________________
2011 GMC Sierra 3500HD gas 6.0 dually
1994 K1500 Suburban shop mule and plow truck
2006 Lakota 29RKT 5th wheel
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10-26-2024, 11:32 AM
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#4
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Senior Member
Join Date: Nov 2015
Posts: 27,919
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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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Dodge 3500 w/Tractor Motor
US NAVY---USS Decatur DDG-31
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10-26-2024, 01:53 PM
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#5
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Junior Member
Join Date: Jun 2011
Posts: 7
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Quote:
Originally Posted by kdauto
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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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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10-26-2024, 03:13 PM
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#6
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Senior Member
Join Date: Dec 2023
Posts: 577
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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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10-26-2024, 03:36 PM
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#7
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Junior Member
Join Date: Jun 2011
Posts: 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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10-26-2024, 06:43 PM
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#8
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Senior Member
Join Date: Apr 2003
Location: Kelowna, B.C. Canada
Posts: 3,579
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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.
Dave
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2022 Outdoors RV 25RDS, 2022 F350 dually, 6.7PSD, 10 spd, 3.55's
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10-27-2024, 07:58 AM
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#9
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Senior Member
Join Date: Jul 2017
Posts: 870
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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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10-28-2024, 07:14 AM
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#10
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Junior Member
Join Date: Dec 2023
Posts: 24
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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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10-28-2024, 03:39 PM
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#11
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Senior Member
Outdoors RV Owners Club
Join Date: Dec 2019
Posts: 682
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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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10-29-2024, 10:51 AM
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#12
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Senior Member
Join Date: Apr 2003
Location: Kelowna, B.C. Canada
Posts: 3,579
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Quote:
Originally Posted by BPTS
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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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
2 cents
Dave
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2022 Outdoors RV 25RDS, 2022 F350 dually, 6.7PSD, 10 spd, 3.55's
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11-08-2024, 09:18 AM
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#13
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Junior Member
Join Date: Jun 2011
Posts: 7
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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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11-08-2024, 09:47 AM
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#14
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Senior Member
Join Date: Apr 2003
Location: Kelowna, B.C. Canada
Posts: 3,579
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Quote:
Originally Posted by jagcyn
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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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.
Dave
__________________
2022 Outdoors RV 25RDS, 2022 F350 dually, 6.7PSD, 10 spd, 3.55's
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