Help!
I currently have a 04 DRW 6.0, not four wheel drive. After about 5000 miles I noticed fuild leaking from my front seal of the rear end. Where the drive shaft enters the rear end. A chattering sound is also coming from rear during slow starts and turning right or left also when backing up. Vibrating the whole truck.
Took it to my Ford dealership were I purchased the vehicle. They replaced the seal and the clutch pack. The same happened again. The truck has been in again 4 times for same propblems. The last time, the owner of the dealership said he would replace the whole rear end. When I went to pick up the truck they said they found the vent tube plugged or capped, they unplugged it and replaced the clutch pack..... It is still leaking!

Is the drive shaft bent? Any ideas?
35,500 miles on truck now, 500 more no more warranty!

Eric Baker

 

If you bought it new I would seriously start throwing the word LEMON the dealers way. When they hear LEMON or BAD FAITH they will get it right. I would make them replace the entire wheel hub to hub. as well as the driveshaft. What does the dealer care anyways ford will foot the bill.

 

Is the vibrating still there or is it gone? Sounds like the vent tube was blocked and the first time and blew out the second seal as well before they found the problem. Sounds like you need another new seal. Take it back until theyget it right? The sooner the better.

 

palmetto... not sure how the lemon law works in you state, but that certainly is a thought to put in the dealerships ear. We give the dealerships a good amount of money for these trucks , and in good faith(warranty hopefully/cash) we want them to fix what is wrong. And they are only human so sometimes it might take a couple of trys to pin piont the problem. But after 4 times they should start to look at something more than what they keep fixing. Hope they find the problem....keep us updated,somebody else might have or had this problem too.

 

It sounds like to me that the vibration was caused by the clutches needing a little friction modifier not replacement. The seal leak was probably caused by the plugged vent tube and if they didn't replace it after finding the plugged tube the second one probably met the same fate.

I had my pinion seal fail at 34K, I had it replaced at a local dealership with no problem after that but the dealership also deals with trucks 90% of the time and the service tech is a friend ( we are in the same American Legion ) he also has been a Ford Tech for 45+ years way before they were called Techs. He showed me how he marked the pinion yoke and shaft end to make sure the crush sleeve went back to the same place the it was set up at the Dana factory. If they didn't do that it well cause a lot of problems in the future. The DRW seem to have more problems with the clutch chatter than the SRW do, and it does feel like the rear end is coming apart and it will shake the hole truck. I would contact Ford and tell them the problem and they may find you a Dealership that deals in trucks. Like my Friend told me this is a Heavy Truck rear end not a light weight truck rear end.

Denny

 

I have the exact same symptoms with my 01 F250 with 90,000 miles. About a month ago I was driving in the snow in 4wd Hi and there was a loud klunk at about 60 and it popped out of 4wd. It was shuttering during turns a month or so prior to this however, so I don't think the two are related. Could I be wrong? I spent a couple of years as a dealership mechanic but mostly light duty and front wheel drive stuff and it seems like an eternity ago. It sounds like I need to get up to speed on rear ends. Any suggestions for some online reference resources would be greatly appreciated. Good Luck Palmetto and please keep us posted on the outcome.