Have Your Differential and Transmission Fluids Checked! Low Fluid Levels from Factory. Expensive Problems

[Chase65]

I I have 2 Bronco Sports. Both 2021 year models. One is a FE and the other an OBX. FE has 70,000 miles, OBX has 45,000. Both had incorrect fluid levels in one or both of the differentials, and the OBX also had the incorrect fluid level in the transmission. Here is my account of this ordeal. The biggest problems were with my OBX. About two months ago, a slight noise was noticed coming from the rear of the car, especially when turning to the right. I wasn't really sure what it was but it didn't go away and it started to get louder and more noticeable. I decided to take it in and have it looked at and that's when I was told it would need a new rear differential. They said the damage was already done and nothing could be fixed. This vehicle has only ever been on the highway and has been driven very conservatively. I questioned why it had failed and was told it was due to the gear oil being low. The new rear differential took about 3 weeks to arrive and was about $1400. I didn't leave the car at the shop that whole time, I continued to drive it around town in the meanwhile as the damage was already done. When the new differential finally arrived, I told them to check the fluid level on the front differential and also on the transmission. At this time, I also scheduled my FE to go in and have all the same fluids checked on it just to be safe. On the FE, the rear fluid level was fine and the transmission level was fine, but the front diff level was low. I had them top it off and that was that for the FE. Now back to the OBX, while it was in there for the new rear diff and having the other fluids checked, the report came back that the transmission and front diff had the incorrect levels of fluid and both were low. The front diff was topped off, the transmission was apparently low enough that they felt the need to open it up and the report was that there was metal in what fluid it had and that a screen/filter was clogged in the valve body. Now, after this point, I'm not exactly sure what happened or why. I had never had any transmission issues or suspected any issues with the transmission on this car, but I told them to fix what needed fixed and fill it up with the correct level of transmission oil. This was done and then the car wouldn't go into gear. Neither forward or reverse worked. After some back and forth with the shop, it was finally determined that the valve body needed replaced. So more time in the shop and more money out the window. All in all it was around $4000 for all the repairs on the OBX and it's back on the road driving perfectly fine now. We just completed a 1,500 mile trip over Thanksgiving with both vehicles and noticed no problems at all. Happy to be back on the road, but frustrated in the problems and with the experience that I've had. I know there are others that have shared having to have the differentials replaced, I just wanted to chime in and say that yes, this is a problem that I can confirm with both my Bronco Sports. Maybe it'll save someone else some money and a headache down the road. Picture is just showing my Broncos. You may notice the exhaust hanging down on the FE....that's for another post

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[Area51BS]

Our HE goes in tomorrow for the rear drive unit noise while driving slow and/or hard turn

 

[Chase65]

Hopefully you don't have to have it replaced. It's sad this is a persisting problem.

 

[Uncle Brad]

For what it's worth, in addition to this low-fluid-level problem, there may also be a problem with the quality of the oil itself. In my full-sized Bronco, the manual transmission made noise when cold, at startup, since it was picked up from the dealer a year ago. Changing the oil to a good-quality GP-4 synthetic literally transformed the transmission and its shifting. True, the manual in the big Bronco is made in China (not Mexico) but maybe it's worth keeping in the back of our minds.

 

[Chase65]

For what it's worth, in addition to this low-fluid-level problem, there may also be a problem with the quality of the oil itself. In my full-sized Bronco, the manual transmission made noise when cold, at startup, since it was picked up from the dealer a year ago. Changing the oil to a good-quality GP-4 synthetic literally transformed the transmission and its shifting. True, the manual in the big Bronco is made in China (not Mexico) but maybe it's worth keeping in the back of our minds.

Yes, I have heard something about the quality of oil being a problem too. Definitely something to consider. My shop had to special order the oil they used to top off my diffs.

 

[Stircrazy]

I I have 2 Bronco Sports. Both 2021 year models. One is a FE and the other an OBX. FE has 70,000 miles, OBX has 45,000. Both had incorrect fluid levels in one or both of the differentials, and the OBX also had the incorrect fluid level in the transmission.

did you do the transmition services at the recomended intervals, or was this the first time it went in? at 70000 it should already of had two drain and fills done, which each time would have set the level properly.

 

[rocks]

Yes, I have heard something about the quality of oil being a problem too. Definitely something to consider. My shop had to special order the oil they used to top off my diffs.

Ford cutting costs. The deletion of parts over the last few years and now cheaper grade fluids. WTF!

 

[dedwards0323]

My 2021 Outer Banks is just starting to have this noise from the rear differential. Fortunately, my Bronco Sport was a Ford Gold Certified used vehicle when I bought it and the 7-year warranty on the powertrain doesn't run out until 09/22/2028 or 100,000 miles. Replacement should only cost me $100. My 2021 goes into local Ford dealer for a 'look-see' on Monday, 08/17. I'll make sure that fluid levels on both differentials and the transmission are checked. Based on what I read in this thread, the rear differential will probably need to be replaced.

A copy of this thread will be left in my Bronco Sport for the Service Tech to review. You would think Ford would issue a recall to have the differentials & transmission fluid levels checked if the factory didn't properly fill them.

 

[dedwards0323]

Local Ford Dealer called me this afternoon & told me that the Rear Diff has started a failure mode & will need to be replaced. Turns out Rear Diffs are backordered by Ford & the Service Advisor told me one probably wouldn't be available until late this week or early next week (forecasted availability). So I told them to button up the Rear Diff, get it refilled with gear oil & I would pick the Bronco Sport up & drive it locally until the replacement hardware was available.

Service Adviser told me they were having to replace quite a few Rear Diffs on Bronco Sports. He relayed a Tech Bulletin they have that states a drain line, for getting moisture away on the Rear Diff, gets plugged up & since oil & water don't mix well, the diff begins to fail. He stated that the Tech Bulletin states to replace the Rear Diff & install a new Drain Line.

Not sure whether I buy this failure mode of the Rear Diff, but since I have the Gold Certified Powertrain Warranty until SEP/2028, this repair only costs me the $100 deductible.

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