Clunk from rear end on acceleration. (Differential Replacement)

[sikedsyko]

Just wanted to document an issue here that I hadn't seen posted.

Very early production 2024 Raptor. Started noticing a clunk feeling in the drivetrain when accelerating from a stop around 45k miles. Dealership noted the issue, reset the transmission adaptation. Didn't really do anything. It was pretty subtle at this point.

Took it back around 50k miles and dealership had the truck for 2 weeks before telling me they couldn't replicate the issue and leaving me on the hook for 2 weeks of rental car.

3rd time its back at a different dealership at 55k miles. Clunk has gotten much more noticeable, happens basically everytime you accelarate.

Dealership diagnosed rear differential failure. They wanted to replace the whole differential, but parts are back ordered to October. They're going to order a rebuild kit for the diff and hopefully have it back in a couple of weeks.

I saw reports of early Rangers having underfilled differentials. I'm guessing thats what happened here and its finally worn itself down enough to cause issues.

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[got3fords]

I really hope when they open it up if they can determine the cause. If it was indeed under filled. That sucks!

 

[Jason B]

First thing I thought, yep that slip yoke need greasing.
Apparently, it's not that easy.
Are you still able to drive it, or is it stuck with the dealer?

 

[bgn]

Absolutely asinine to me that Ford is underfilling fluids. Same thing happened on the Mavericks.

 

[stuartmunto]

I doubt it was undefilled diff oil. The whining sound it makes when low on diff oil is very obvious (especially when up at speed)

the low diff oil was only a thing on Thai build rangers and only on the very first batch (2022 models)

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