3 weeks having it would be an understatement for time into it. Ford can build a few new trucks in that time.

 

I have the same issue with my ‘21 F250 6.7 10spd 3.31. 2 weeks old. Did it from day one. Been ignoring it. 4th gear, 1100 rpm grind. Any updates or resolution?

 

I bought a new 2022 F250 6.7 last week and noticed this noise on the way home. Took it to the shop the next day and it's been there since.

I'm not sure if it's the same thing but check out this 2022 with 6.7 a Ford Tech diagnosed to be wobbling driveshaft that damaged rear end:


At the 5:40 mark you can see the mechanic demonstrating the noise on a test drive with his Chassis Ears

You Tube

At the 10:14 mark you can see the crooked counterweight/pinion flange on rear of driveshaft wobbling



Watch from beginning, he explains driveshaft & counterweight/pinion flange replacement & also rear-end rebuild

 

Yup that’s my truck. Been without it a month now. Last I heard Ford is looking for an axle for it as i am refusing a rebuild and there aren’t any axles. Dana is going through some issues. I have a feeling there’s gonna be a lot of trucks popping up with this issue. Probably using cheap bearings due to this “shortage”. I’ve been on the phone with customer care everyday and my next step is telling them to just buy it back. I’ll find a 17-19 truck and wash my hands of it.

 

Oh wow - so the driveshaft, new counterweight and rebuilt rear-end didn't fix the noise? I guess that means I'm screwed because my truck has the exact same thing going on. I'm glad I took it back almost immediately with 200 or so miles on it.

I've had to do Ford RAV (buyback) program before. It's a huge pain in the *** and many months of phone calls, dealer visits, table flipping to get approved.

 

They haven’t rebuilt the rear end yet I told them I am not accept a rebuild on a brand new truck so they’re trying to source a complete axle so I’m just waiting in the meantime to see what they can come up with.

 

I would trust your local technician/mechanic in that video much more than a new Dana axle. Wasn't the issue caused by the drive shaft wobble, which then damaged the bearings and rear end? A rebuilt rear end with an extended warranty might be better than a new axle.

 

I am happy to hear that they will accept your "want a NEW one' !
I have a vibration that they can't find but think it is more the front end. But thanks to this I will be double checking the drive shaft

 

what ended up happening is that pinion flange was installed improperly from Dana so that’s why it was wobbling. Probably ate the pinion bearings to hell during the 1300 miles of me driving it like that. Originally that was the plan of a rebuild until I threw a fit about it. You’re not wrong, I trust the tech working on it he’s a great dude I was so pissed at the time and sick of paying on this truck that I don’t have that they are trying to source a new unit and rebuild as a second option. What’s strange is there’s a few people in this thread with the exact issue and we all have different trucks. Single wheels mines a dually. It’s just weird the noise we are all hearing

 

Thanks for the clarification Aad2797. I think at this point I'd let them just rebuild the rear end in mine so I could drive the thing. I bought it last week because I was buying a new RV (which I'm supposed to pick up this weekend)

Mine is 100% the same noise mine is SRW 2022 CCSB 4x4 6.7 STX.

Put $15k cash down on mine and make the first payment in a few weeks and I got to drive it for about a day (with it making this ****ty noise on decel).

 

What was the issue with that SPRING support making the metal noise? Was that issue separate from the whole drive-shaft and axle issue. I'm the one that has a STERLING axle that is seeping oil out of the actual housing. Not from a seal. Seem like wether its DANA or Sterling issues can happen. I too am refusing a patch type job and demanding a new rear axel. I hope the STERLING's are easy to come by.

 

Spring I think was just lack of grease above the isolator. With some weight in the truck I wouldn’t even notice it. I too put 10k down on this truck and drove it for about a week. Just made a payment and now have to fight Ford for payment reimbursement and still without a loaner! I got this truck for a 5th wheel camper that thank god I didn’t purchase yet. Traded in my perfectly good 2019 on this truck so I’m not happy at all. I could put the truck in manual mode like he stated in the video get to 3rd gear and coast with no brakes let it decelerate and the noise is horrendous!

 

That sucks on the 2019. I too have made a mistake on trading in a perfectly good truck with 0 issues EVER on something that gave me problem after problem (Jeep Wrangler). I hoping this axle leak I have with my 21 is the only major issue I get. My dealer seems to be good about it though.

 

What’s strange to me is we all have this noise and we all have different trucks with different axles. Some gas some diesel. Sterling 10.5, Dana M275 and my Dana M300 all grinding 4-3 downshifts. Transmission? Rear ends? Whatever it is, it is not normal. This is the third dealership I had to take it to for someone to finally agree with me that this sound isn’t normal. I laughed in their faces at the other dealerships saying this is normal noise. Get outta here! I’m around these trucks every third day at work and none of those trucks make this sound. Hopefully there is an end in sight!

 

I hate to say it but Trans sounds like likely culprit. Although your rear-end was clearly shot too.