'22 Maverick Lariat 2.0 AWD Ecoboost REAR DIFF

[Marc_in_CT]

Back in March of 2023, at 19k mikes I started complaining of a noise coming from the rear. It was a weak clunk or thud at take off and would go away after 15 mph or so. From there it progressed slowly getting more obvious and louder. Each oil change, and two specific visits for the noise it was said to be "not found". Last month, 58k I had enough and had the oil changed and asked them to keep it to find the house once and for all. Again, "not found". 4 techs, multiple multiple vists and noone has heard or felt a thing. So today I took it back and took a tech out for a ride. 10 seconds, 5mph and still in the lot the tech now hears it. FINALLY!!! On the lift it goes, 20 minutes later and a rear diff fluid sample tells the story........LOTS OF METAL SHAVINGS. Thank god now cuz I'm 1500k away from out of warranty.
Anyway, to answer some possible q's, no lifts, no mods and only towed a small trailer once. No other issues except the half dozen recalls taken care of along the way. No off roading and never beat on it. Anyone else have to replace a rear differential yet?

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[Toddman45]

Ford's had a lot of issues with their PTUs on these smaller all wheel drive vehicles it's a known issue and has been if you do a little research on YouTube plenty of burnt up PTUs and all-wheel drive units as well.

For used to say they were lifetime and there was no easy way to change them but once they replaced a good number of them they finally started making them serviceable. If I recall most of them weren't even filled to the proper level, and they were also close to the exhaust which help heated the fluid up.

 

[BlueMav43]

Bronco Sport forum has lots of comments about RDU failures. Think the BS has a TSB concerning a RDU vent hose.

 

[Nw_adventure]

Learned years ago with the Honda Elements part time AWD- Rear Diff- Be changing that fluid often.

 

[Automan21]

I agree with the fluid not being filled to proper level. Cremated mine a few weeks back and swore it was like half a quart or less.

 

[tciotti2003]

So when I 1st purchased my used. 22 1st edition lariat it had 20k miles. I read here in the forum about low levels of fluid in the PTU and RDU so I went ahead and had all the fluids changed. No matter what I would highly recommend doing this with the 1st 10k miles

 

[CajunMick]

So, reading these reports, suggestions, guess I will have all running gear checked FIRST before any fluid change. Then let tech change fluids. I might have to argue with service writer over this, let him know what’s happening with other owners and to do fluid level check prior to draining, to learn if any impropriety exists.

My truck has ~44XX mikes now. Engine oil was changed at ~1500 miles.

When I went shopping for Mavericks, tried to shy away from any 4x4 or AWD. But this one popped up, it being a AWD so forced myself to get it. So far, it’s doing well.

 

[420Welder]

Back in March of 2023, at 19k mikes I started complaining of a noise coming from the rear. It was a weak clunk or thud at take off and would go away after 15 mph or so. From there it progressed slowly getting more obvious and louder. Each oil change, and two specific visits for the noise it was said to be "not found". Last month, 58k I had enough and had the oil changed and asked them to keep it to find the house once and for all. Again, "not found". 4 techs, multiple multiple vists and noone has heard or felt a thing. So today I took it back and took a tech out for a ride. 10 seconds, 5mph and still in the lot the tech now hears it. FINALLY!!! On the lift it goes, 20 minutes later and a rear diff fluid sample tells the story........LOTS OF METAL SHAVINGS. Thank god now cuz I'm 1500k away from out of warranty.
Anyway, to answer some possible q's, no lifts, no mods and only towed a small trailer once. No other issues except the half dozen recalls taken care of along the way. No off roading and never beat on it. Anyone else have to replace a rear differential yet?

I talked to a Ford technician at a motorcycle race in Pittsburgh a few years ago when my daughter just bought her Hybrid Maverick. He said good thing she bought the Hybrid, the AWD version uses a transfer case that only holds 1 pint of lubricant and it’s worth while to service it more regularly than the manual says. Good luck.

 

[Bwicka]

A lot of people confusing the rear differential on his original question with the ptu.

 

[jewc75]

The rear differential will start clunking when the fluid breaks down. Mine did it at 27k miles. I changed the fluid and the noise went away. Its been noise free for 10k miles.

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