Bronco Sport badlands 2022 Rear Differential Problem (Grunching sound)

[eugeniodb99]

Hi everyone,

I have a 2022 Bronco Sport Badlands, and I've been dealing with a problem with the rear differential. For a while now, I've been hearing a strange noise that sounds like "grinding" or something stuck coming from the rear. It’s really concerning because it seems to be coming from the differential.

I took the vehicle to my local Ford dealership, and they changed the differential oil, but instead of fixing the problem, it actually made the noise worse. Now, I’ve been waiting for a “RDU Vent Hose” that they said would solve the issue, but it’s been over 5 weeks and I have no idea when the part will arrive.

I’m attaching a video where you can hear the noise the vehicle is making.

I don't think the "RDU Vent Hose" from the TBS 24-2185 will fix the problem. From the sound, I do think I am going to need to change the whole real axle including the differential.

Should I continue to drive like this? My local dealer told me there was no problem and would not affect the warranty.

What do you guys think?





Thanks

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[Quashish]

Obviously not good. Don't know why your dealer said keep driving.

Doesn't sound good or normal on any way. How many miles?

 

[V8 Yankee]

Houston you have a problem. It might be drivable but you better not drive it very far from the dealer. I had a complete replacement of my RDU and drivers side axle at 40K. The dealer threw in the updated vent hose too. Altogether it totaled 4k, that included a rental for almost two weeks. I paid zero out of pocket as it was captured under the drive train warranty. I'd be wary of a verbal, "you can drive it" statement. If its not in writing it didn't happen. The dealer might come back on that as sometimes selective amnesia kicks in when it comes to that sort of thing.

 

[eugeniodb99]

Obviously not good. Don't know why your dealer said keep driving.

Doesn't sound good or normal on any way. How many miles?

25,000 miles

 

[eugeniodb99]

Houston you have a problem. It might be drivable but you better not drive it very far from the dealer. I had a complete replacement of my RDU and drivers side axle at 40K. The dealer threw in the updated vent hose too. Altogether it totaled 4k, that included a rental for almost two weeks. I paid zero out of pocket as it was captured under the drive train warranty. I'd be wary of a verbal, "you can drive it" statement. If its not in writing it didn't happen. The dealer might come back on that as sometimes selective amnesia kicks in when it comes to that sort of thing.

Thanks for the response harold.

My local dealer insists that the problem is only "RDU Vent Hose".

Since my warranty only has about 10,000 miles left i will need to be very careful.

Thinking of extending it.

 

[Paradocks]

In the video it looks like you have 4WD lock activated. Why are you using 4WD lock on dry pavement? I thought that was extremely bad on the drivetrain as it could cause binding leading to excessive noise and potential damage. 4WD lock should only be used in conditions where the wheels can slip.

 

[eugeniodb99]

Hi doug,

Thanks for the comment. Its my first time with a SUV with differential.

On a sidenote, I have only used 2 times the 4WD lock on sand and mud terrain. I do not use it on paviment.

 

[Cursed Bronco]

I've been driving with mine like this for 3 months because the parts to "fix it" have been on backorder. I put that in quotes, because it pretty much only fixes it if you catch it early. The underlying problem is a vent hose that allows debris to come in and contaminate the differential fluid, leading to the sensation of binding in the differential. From anecdotal evidence of reports I have seen, the replacing of the hose and a fluid exchange doesn't fix it, then an RDU rebuild is in order.

My parts finally came in, and I am getting it addressed on Monday, but I don't believe it will be fixed at this rate given the time before it was diagnosed, and the months of driving afterwards.

Take this with a grain of salt, but I believe you should be fine to keep driving it. It likely won't grenade on you, but you will probably need an RDU down the road because I doubt your dealer will have the parts to perform the TSB on the differential.

 

[DawnMichelle]

Currently having same issue with my '22 Big Bend. Dealer just replaced the RD vent hose which only made noise worse and more frequent. They have ordered parts to replace the rear axle next week. Also told me it was safe to continue driving but that didn't really ease my mind. Less than 25,000 and already had multiple issues and recalls. Making me reconsider the purchase.

 

[Nam3]

I had a grinding noise after offroading with no plates. Turns out I broke these mounts and the shielding was hanging down and griding against the driveshaft. Ford also told me that they changed the oil in the rear diff because of foreign contaminents before finally coming back and replacing these mounts. It's hard to tell if it's the same noise or not but check and see if there's any scratching on the driveshaft like you see in my pic. After breaking it yet again, because I never learn my lesson. I currently have the shielding held up with zipties and it's been fine for a few months that way.

 

[cvreeland]

Same issue here—also been waiting for 5 weeks with zero idea of when parts will come in. Ford seems incredibly unconcerned about the number of Broncos piling up at their service centers.

 

[RSH]

Hi doug,

Thanks for the comment. Its my first time with a SUV with differential.

On a sidenote, I have only used 2 times the 4WD lock on sand and mud terrain. I do not use it on paviment.

Technically you have used 4WD lock at least 3 times, sand, mud and pavement.
Did the RDU make noise when you previously used 4WD lock when driving on sand or mud?
If you have accidently been driving in 4WD lock on pavement for extended periods of time that will damage the RDU and it will not be covered by the warranty, hopefully that's not the case.

 

[Ford Motor Company]

Currently having same issue with my '22 Big Bend. Dealer just replaced the RD vent hose which only made noise worse and more frequent. They have ordered parts to replace the rear axle next week. Also told me it was safe to continue driving but that didn't really ease my mind. Less than 25,000 and already had multiple issues and recalls. Making me reconsider the purchase.

Hello, Dawn. Are you still experiencing this noise concern? If so, I would like to look into it on my end. Please send over a private message with your VIN and the name/location of your local Ford dealer.

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