Symptom Chart - Front Differential
WARNING: This page is about a different car, the 2024 Ford Transit-350 HD, 2024 Ford Transit-350, 2024 Ford Transit-250, and 2024 Ford Transit-150. However, it is still accessible from the selected car via links, so may be relevant.
| Condition | Possible Sources | Actions |
|---|---|---|
| Axle overheating | Axle lubricant low | CHECK the lubricant level. FILL the axle to specification. REFER to: Specifications . |
| Incorrect or contaminated lubrication type | INSPECT the axle for damage. REPAIR as necessary. DRAIN and REFILL the axle to specification as necessary. REFER to: Specifications . | |
| Bearing preload adjusted too tight | If low mileage unit, CHECK the ring and pinion for damage. INSTALL new front axle as necessary REFER to: Axle Assembly . | |
| Excessive gear wear | INSPECT all the axle gears for wear or damaged. INSTALL new front axle as necessary REFER to: Axle Assembly . | |
| Broken gear teeth on the ring gear or pinion | Insufficient lubrication | INSTALL a front axle assembly. REFER to: Axle Assembly . |
| Differential side gears / pinion gears are scored | Incorrect or contaminated lubricant type | Drain and FILL the axle to specification. REFER to: Differential Draining and Filling . Road test vehicle. If an observable symptom is present (noise from front axle), INSTALL new front axle assembly as necessary. REFER to: Axle Assembly . |
| Front axle will not Disconnect or Front axle will not Connect | AWD Calibration | Normal AWD module operation is to command Front Axle connected state when: Ambient temperature is below 3deg.C (37deg.F) Windshield wipers are in the MAX or high-speed position Deep Snow / Sand or Slippery drive mode is selected |
| Wiring / relays | Refer to Diagnosis and Testing DTC chart in Four-Wheel Drive Systems . | |
| AWD module | Refer to Diagnosis and Testing DTC chart in Four-Wheel Drive Systems . | |
| Transfer Case Clutch stuck applied | Normal AWD module response is to keep Front Axle connected if transfer case is transferring torque to front driveline. RESOLVE all transfer case concerns. Refer to Diagnosis and Testing DTC chart in Four-Wheel Drive Systems . | |
| Transfer Case Clutch not transferring torque | Normal AWD module response is Front Axle disconnected if transfer case cannot transfer torque to front driveline. RESOLVE all transfer case concerns. Refer to Diagnosis and Testing DTC chart in Four-Wheel Drive Systems . | |
| Differential Side Gear | INSTALL new a front axle assembly. REFER to: Axle Assembly . | |
| Lubricant leaking from the pinion seal, axle shaft oil seals | Vent | CLEAN the axle housing vent. |
| Damage in the seal contact area or pinion flange dust shield | INSTALL a new pinion nut and the pinion seal if damage is found. REFER to: Drive Pinion Seal | |
| Damage in the seal contact area | INSTALL a new halfshaft seal as necessary. Inspect Halfshaft seal contact area. Install new halfshaft as necessary. REFER to: Axle Shaft Seal . | |
| Grease expelling from pinion splines | Missing / worn / damaged driveshaft to pinion circlip Missing / Damaged front axle pinion stem O-Ring |
REMOVE the Front Driveshaft. INSTALL New Circlip and O-Ring. INSTALL the new Front Driveshaft as necessary. REFER to: FRONT DRIVESHAFT - LHD AWD |