NHTSA Complaint #10122221 — 1999 FORD F-150

A HIGH PITCH NOISE COMING FROM REAR AXLE ASSEMBLY AND SUBSEQUENT FAILURE OF THE ENTIRE REAR AXLE ASSEMBLY. DEALER MECHANICS HAVE FOUND FOREIGN COMPONENTS INSIDE THE REAR DIFFERENTIAL ASSEMBLY (A SILICON SEALER SQUEEZED AND WEDGED BETWEEN THE RING PINION GEARS AND THE INPUT SHAFT) THAT MAY HAVE CAUSED THE PROBLEM. THEY FOUND THE REAR AXLE LUBRICANT TO BE BURNT AND METAL DEBRIS WAS ALSO FOUND INSIDE THE CASING OF THE DIFFERENTIAL ASSEMBLY. VEHICLE FAILED AT AROUND 55,000 MILES AND 6 YEARS OF SERVICE. REAR AXLE HAVE NOT BEEN PREVIOUSLY SERVICED BY ME OR ANY OTHER SERVICE FACILITY BEFORE THE ABOVE MENTIONED FAILURE. THE VEHICLE WAS PURCHASED NEW AND IT HAS BEEN IN MY POSSESSION EVER SINCE. TO SOLVE THIS ISSUE AND MAKE THE VEHICLE DRIVABLE AGAIN, A $2,500.00 WORTH OF REPAIR (DEALER RECOMMENDED REBUILD OF THE ASSEMBLY) HAD TO BE PERFORMED. FORD IS DENYING ANY CLAIMS THAT I HAVE MADE IN ORDER TO RECEIVE ASSISTANCE. OLD PARTS AND THE FOREIGN COMPONENT HAVE BEEN SAVED AND ARE IN MY POSSESSION. I BELIEVE (WITH THE SUPPORT OF THE SERVICE REP. AND THE MECHANIC) THAT THE POOR ASSEMBLY PROCEDURE AT THE FACTORY AND THE FOREIGN PART FOUND IN THE FAILED COMPONENT TO BE CAUSE OF THIS PROBLEM.