2021 BS OB | Car makes weird "jerk" feeling when slowly turning right

NewStockyBalboa

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Hi.

I had a post on this last year: https://www.broncosportforum.com/forum/threads/2021-bs-ob.12092/

This is the same dealer I purchased the car and have done every service at it as well.

Circling back to this because I brought it back to the dealer for 60K maintenance, my car is at 76K miles. The 60K service consist of oil change, oil filter, transmission oil flush, coolant flush, and tire rotation. A $750 service. I requested a master mechanic to be looking at my car because a year later, and the car still makes that ever so slightly "jerk" feel when turning right, mainly forward. I brought it up to them last year when I first got the brakes, tires, and rotors replaced. They said everything looks fine. I do not trust there troubleshooting. As evident from one of my other posts where this sub saved me.

Well this past weekend, I heard a grinding noise coming from the front passenger wheel, thankfully I was in a grocery parking lot. I stepped outside to look, I didn't notice at first, but I did a triple check, took 15 minutes, but there is a clip missing from the front passenger brake/rotor assembly, while the other three wheels have that clip. I didn't say it to the dealer service center when I dropped it off this morning to see if they would mention it. The mechanics sent out a video describing what they "found" while doing the service and trying to address my comments/complaints. He said it looks like the differential is bad and needs to be replaced. That does not sound right to me. They never mentioned the missing clip. So I called the service center and spoke to the service person, and said how come he didn't notice the clip? She said "the noise is not from the clip missing, its from the differential, the mechanic is working on getting you a quote." The car is under extended warranty. But that doesn't sound right at all to me. I asked her if that is a safety concern? She said "I will ask the mechanic but that it is your differential as that is what the mechanic found".

Any ideas?
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Dude

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The RDU is a known problem for some Bronco sports, if that’s an issue for yours the grinding sound would be coming from the rear when turning right I think. Let’s see if they replace the RDU under your extended warranty, or if they replace certain parts per the current TSB (search for RDU and you’ll find many posts), or if they take the easy way out and just drain / refill the RDU fluid (plus install the upgraded RDU drain tube if needed).

Since you hear the sound from the front, that right missing clip will also need to be addressed.

Let us know later after all the work is completed and the grinding issue (like driving in soft snow) is resolved as to what was found and replaced / fixed.
 
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NewStockyBalboa

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Update:

Wanted to circle back with some details after today’s dealer visit.

The grinding noise I mentioned earlier was not from the RDU itself, that only happened because the retaining clip on my front passenger brake assembly had fallen off. Once that was gone from the wheel area, the grinding stopped. But the jerking sensation at low speeds while turning the wheel fully to the right is still there, which I’m hoping the differential (RDU) replacement will resolve.

From the dealer side:
  • The 60K mile service (oil + filter, coolant flush, transmission flush, tire rotation) came to $811.
  • They originally told me I had to pay $10 for the missing clip, but when I asked if a manager could review that, the service advisor said she wouldn’t escalate it over $10 and just waived it.
  • The RDU is backordered until the end of the month. They opened a ticket under my Ford warranty, so once the part and clip arrive they’ll reschedule me for the repair.
For now, the car is fine to drive, but I’ll update again once the RDU is swapped out.
 
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NewStockyBalboa

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Update: issue resolved!

I followed up with my service advisor in the second week of October after realizing they had forgotten to schedule my repair. This time, they were actually great and got me in last Monday (10/13) for a drop off. I figured it’d be a one or two day job, but thankfully I had requested a loaner (which they hate giving out).

For context, I’d mentioned this noise to them during my last three oil changes, and each time they said, “Oh, the mechanic checked everything, it’s fine.” But as soon as I mentioned that my car is under extended warranty and should be covered under warranty, suddenly they “found” the issue. Not saying anything, just an observation.

Turns out, when the tech finished replacing the rear differential and went for a test drive, he heard a knocking sound from the engine bay. Sure enough, bad motor mounts. Those were replaced under warranty too.

They had the car from Monday morning through Thursday evening. Now it feels good again, almost like the day I first bought it.

The differential replacement fixed the low speed jerking and noise, and the new engine mounts completely got rid of the knocking. The only small miss was that they forgot the clip that goes on the brake caliper. I went back and pointed it out, and they said they'll take care of it at my next oil change.

And just when everything looked perfect, my CarFax updated… and Ford issued yet another recall, this time for the fuel injectors.

Since ownership (bought brand new in May 2021) here are the non-recall repairs and maintenance:
1. EVAP Solenoid
2. Brakes, Rotors, and tires at the same time (issues started after these were replaced in May 2024)
3. Water pump
4. Motor Mounts
5. Differential
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