NEED HELP: 2011 4.0 4wd front axle seal failure - FordTough.ca - Home of Canadian Ford Truck Enthusiasts
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post #1 of 7 (permalink) Old 02-04-2016, 08:33 PM Thread Starter
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2011 4.0 4wd front axle seal failure

Hi all, just wondering what could be causing my front axle seals to be failing. The truck is on its 3rd set of axles with just over 100k.

Truck is not abused, just normal use. All repairs done at my dealer with Ford parts and labour.

Any ideas what could cause the repetitive failure? Ford doesn't seem to know. Thanks for your help
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post #2 of 7 (permalink) Old 02-05-2016, 10:17 AM
 
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Is there any contaminants in the fluid? Have they changed the fluid, or do they just add to it? Are they putting the correct fluid in it? Is it at the correct level? Go to Oil Analyzers and see if they can test the fluid.

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post #3 of 7 (permalink) Old 02-27-2016, 10:51 AM Thread Starter
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Yes I had all the fluids changed about 6 months ago, so it's just to wait and see with this set and hopefully they don't leak.

I did hear that occasionally castings can be off, could that be a possibility in the differential something is out of spec?

Ultimately I'll just keep replacing the axles if Ford cant diagnose, I like it and plan to keep it as long as I can.
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post #4 of 7 (permalink) Old 02-27-2016, 01:08 PM
 
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If there is a next time, and you have the shaft out, check the seal surfaces for nicks or scratches.


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post #5 of 7 (permalink) Old 03-06-2016, 09:21 AM
 
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Quote:
Originally Posted by Leder View Post
Yes I had all the fluids changed about 6 months ago, so it's just to wait and see with this set and hopefully they don't leak.

I did hear that occasionally castings can be off, could that be a possibility in the differential something is out of spec?

Ultimately I'll just keep replacing the axles if Ford can't diagnose, I like it and plan to keep it as long as I can.
You may want to ask your Dealership to get in contact with the Ford Tech. brain trust hotline ,available to them via a phone call. They collect all of the various fixes to issues, from dealer techs. across Canada etc.

Your local service dept. may perhaps don't have to training to resolve your problem, or are just stringing you along until your trucks warr. has run out.
I quoted you, because I too had an issue with my transmission tailpiece housing casting, as well as the diff. housing casting. (affecting the seals)

Press on regardless!
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post #6 of 7 (permalink) Old 03-22-2016, 10:26 PM
 
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I would suspect a plugged breather vent or hose.

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post #7 of 7 (permalink) Old 03-22-2016, 11:12 PM
 
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what exactly has been happening to the axles ?

could be the entire housing is not straight or something's not in square (?)
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