3rd rear end replacement- solution?

[pilot10]

So my 06 Screw, 50,700 miles is at the dealership having the rear end replaced for the 3rd time. Due last Friday. Monday I was absolutely promised Tuesday and for sure by Wednesday. When the service advisor called Tues I could tell immediately from his voice that it would be longer- needed to order a shim kit. Today he calls at 4:30 and says do you want the good news or bad news first? Apparently there is some adjusting nut or bolt on the outside of the case and the hole it fits in is rounded out so the case needs to be replaced. The advisor needs to get authorization from the ESP people to see whether they replace just the case or use a complete aftermarket unit.


? if they go with an aftermarket unit is there a a "better" & "best". I have 3.73LS now. It's also a 4x4. I'm looking for a really dependable(as in never having to do more than change fluid). I don't want to get stuck w/ some "cheap" imitation that lasts just beyond the 100k ESP warranty.

Initially I was thinking about 4.10s but then I would have to replace the front as well. This truck has had significant warranty issues(beyond the rear-end) and I don't think it is going to last(with me as owner) much longer than the loan on it- the wife already has mentioned trading it in early twice- so I don't want to spend too much on mods. But if it last 5 years it'll probably have 140k and the warranty expires at 100k.

Thanks,
Tim

[johnboy427]

Have you checked into the lemon laws you might be able to make ford buy it back if the problems are big enough.
-Johnboy

[85e150six4mtod]

Once the case is in spec, you should be good on the diff. Bearing issues are common on these, the out of round though...haven't seen that one here.

Gear noise comes up too, but could be in the set up or problems caused by the bearings.

My '98 Exploder had bearing issues, but is quiet after the fix.

If it's a problem truck, good thing you have the esp. Maybe you trade early, before the esp runs out, and eat a little on the trade, or sell it outright.

[pilot10]

Talked w/ the service advisor- the ESP people have someone in the midwest they get complete units from. It should be here next wed, installed by Friday. Tomorrow will be 12 days in the shop.

Oh did I mention it goes into the body shop for 3-5 more days after the rear end is fixed- thanks to a Porsche 911 making an illegal left in front of me 14 days ago.

Lemon Law here is 18 months or 18k miles.

Those 09's can't come out soon enough- I think I'll try and hold out for a '10.

Tim