Howdy, well, I've had my 04 FX4 Scab since August and never would have guessed that I would have to bring in my truck for this! More of a rant, but maybe the following story will help an owner in the future diagnose a problem before having your new truck in the shop for over a week!

I just reloceated up to Vermont from Florida(by momentary lapse in sanity) and had been using 4HI every once and while on road. However, the truck puilled like crazy to the right -- so bad that I felt safer driving in 2WD in snow. It would grind to a stop, and make noise like crazy when turning. I thought it was my mud tires but switched back to stock for the winter...still the same problem. Then, my ABS light kept coming on, disabling the ABS when it did, and thus making quick stops a bit scary in a new $$$$ truck! Pissed, I headed to the dealer to check on it (as well as some other warranty issues that needed to be addressed).

At first, it was assumed that the wheel speed sensor needed to be replaced. Then it was thought that some re-wiring/computer diagnosis needed to be done on the ABS system. Then it was a new front half shaft, which they ordered the wrong one at first...then ordered some attachment piece for the wrong side! Still not fixed, they decided to check one other thing: the gearing in the rear end and in the front end. And what did they find?

3.73 in the front....3.55 in the rear. FROM THE FACTORY.

They couldn't even find the factory specs of my truck in the computer and had to call the dealer in FL to fax over my original spec sheet to whether to replace the 3.55 or 3.73. (I knew the truck spec'd with 3.55 LS, but was hoping they would just swap the rear to 3.73). After 10 days of being stuck in a crap FOCUS (no power anything!)...and after half my drivetrain ripped apart at 10K miles, I had the correct gears up front. Tranny shifts felt different, but I assume they reprogrammeelt safer driving in 2WD in snow. It would grind to a stop, and make noise like crazy when turning. I thought it was my mud tires but switched back to stock for the winter...still the same problem. Then, my ABS light kept coming on, disabling the ABS when it did, and thus making quick stops a bit scary in a new $$$$ truck! Pissed, I headed to the dealer to check on it (as well as some other warranty issues that needed to be addressed).

At first, it was assumed that the wheel speed sensor needed to be replaced. Then it was thought that some re-wiring/computer diagnosis needed to be done on the ABS system. Then it was a new front half shaft, which they ordered the wrong one at first...then ordered some attachment piece for the wrong side! Still not fixed, they decided to check one other thing: the gearing in the rear end and in the front end. And what did they find?

3.73 in the front....3.55 in the rear. FROM THE FACTORY.

They couldn't even find the factory specs of my truck in the computer and had to call the dealer in FL to fax over my original spec sheet to whether to replace the 3.55 or 3.73. (I knew the truck spec'd with 3.55 LS, but was hoping they would just swap the rear to 3.73). After 10 days of being stuck in a crap FOCUS (no power anything!)...and after half my drivetrain ripped apart at 10K miles, I had the correct gears up front. Tranny shifts felt different, but I assume they reprogrammed or reset something.

What's even worse -- I brought this to my dealer in FLORIDA before I left for the exact same symptoms at 5K. They replaced a wheel speed sensor and told me the tech drove it and making quick stops a bit scary in a new $$$$ truck! Pissed, I headed to the dealer to check on it (as well as some other warranty issues that needed to be addressed).

Other things repaired in thed or reset something.

What's even worse -- I brought this to my dealer in FLORIDA before I left for the exact same symptoms at 5K. They replaced a wheel speed sensor and told me the tech drove it and making quick stops a bit scary in a new $$$$ truck! Pissed, I headed to the dealer to check on it (as well as some other warranty issues that needed to be addressed).

Other things repaired in the warranty trip:
-Leaky back window (non-sliding), fixed by new gasket on high mount stop light
-Brake pulsation up front, fixed with new rotors and pads
-New ABS sensor

Couldn't duplicate:
-Dash rattles
-P/S pump whining after starting when cold (-10)
-Vent flaps whine when moving when cold

I'm glad the dealer up here (Heritage Ford of Burlington) was helpful and on the ball for the problem...gvien all this though, I was hoping they'd at least offer to wash my truck.

Now I feel so much better cruising down back roads up here in the snow... but still have a leaky tire needing fixing, dash rattles every now and then, P/S pump noise, etc.

--Adam
2004 F-150 FX4 Supercab
Daystar level kit, 33" Procomp Mud Terrains on 17" Pro Comp Xtremes (stock rims/tires for winter)

 

Typical dealer answer to pretty much anything you throw at them.

 

Funky double post, won't fix after editing? Sorry for the confusion

 

Sorry alcyone2k1... Server difficulties are causing this to happen in various places on the boards. If you'd like, I can delete this thread and you can take a second stab at posting your issue so that it's more legible.

It has been my experience that editing, typically, doesn't work.

Please email me or post back if you're interested. Feel free to go ahead and re-post if so. I'll delete this one in due time if so.

RP

 

Unreal!

 

Alcyone,

I don't know about you, but i'd be very skeptical of keeping this truck considering the amount of stress placed on the transmission and other drivetrain parts due to the mis-matched axle ratio's. I'd at least get Ford to add an aditional 10K miles to your warranty! Sorry to hear you went through that, but glad it was finally realized.

Sackett

 

If you still have the dash rattle, look at the metal panel directly under/behind the steering column. That is the single only thing that has gone wrong with my truck. There is a metal plate back there, you can reach down and grab it while driving. Mine was missing 2 bolts and the rest were loose. Quality control guy must have been asleep that day in the factory... Took the tech 5 minutes to fix. You can probably fix it yourself if you want. I happened to be in for the 5K service anyway.

KC-10 FE out...

 

Can't blame the dealer completely for this one. I mean, what a freak accident to have differnet gearing. You got the lucky one. Anywho, the dealer techs are using the Ford playbook and past job knowledge... and I doubt either say "Check front/rear gear to ensure they match". As for the other stuff, big deal. When its -10 out, everything rattles and sounds different, with any car you drive. No dealer in the world will 'fix' that.

 

The assembly plant doesn't have gearing laying around on a shelf and someone just happened to grab the wrong one. With the computerized inventory system Ford uses, one thing is almost certain. Another 4x4 has 3:73 in the rear and 3:55 in the front.

It would most likely be the next VIN that was a 4x4.

It would decent of Ford to at least check out the 4x4 that went down the line in front of and in back of this one.

 

Ford should give you an extended drivetrain warranty on your truck. Their screw up put a lot of stress on the transfer case and every other part of the 4X4 system. You shouldn't have to worry about paying for future repairs due to their mistake.

 

Raoul - why not a simple mis-label from the supplier? Or a jokster like myself on a tour swapping stuff around?

 

RockPick: I'll repost, can the replies be forwarded on to the new post?

Thanks for the replies. Working in an ISO9001 manufacturing environment, I know that we have systems to track and account for all sorts of stuff during the manuf. process - lot numbers, post-production tests, and other etc. I figured that to 'grab out of the wrong bin' is highly unlikely in a newly retooled and high-tech Ford fab plant, although mistakes do happen. Which leads me to think that there is another truck out there with 3.55/3.73. Any FoMoCo employees wish to elaborate on the driveline assembly portion at the plant and what steps are taken to prevent this mixup?

Good point regarding the 'extension' for the drive train warranty. I'll see what can be done about that and check with Ford Warranty service. Don't want to harass the dealer about it, since after all, they are the ones smart enough to recognize the mishap and probably can't control my FoMoCo factory warranty.

As for the -10 situations: I know that temperature (especially cold ones) play a part in the fluid dynamics and heating/expansion of various components. The thing is that the rattles and such were present down south, shortly after buying the truck in August. A friend who heads a shop at a Chevy dealer said they get lots of warranty claims for 'trim issues' -noise, fit, etc. Something tells me that, even with the weather, a 30K truck should not be making these noises. Of course, tracking them down is harder than something mechanical not working or making noise.

Git r done!
--Adam

 

I couldn't really tell from the post whether they tore into each axle and held the gear in their hand, which would mean mis-labeled from the axle supplier,
or the two axles on the truck were tagged differently.
If the two axles axles were tagged correctly as to what was inside I would tend to think there is another F150 with the same problem.

The axles arrive at the assembly plant complete. Even at 6-10 you'd be hard pressed to swap them around.

and at 6-10, you'd warrant your own closed circuit monitor.

p.s.
I just recently read in another thread that you were 6-10.
So, just forget about about that other thread where I said I was going to beat you up, make you pay, etc. etc.

 

Yep. I can merge them. No problem. That is, once we get this server thing figured out so that it doesn't keep doing that funky double post/jumbled post thing. I noticed you tried again... Again, I'm sorry it's doing this to you.

What OS/browser are you utilizing?

ISO 14001 as well?

 

True, but in todays cushy factorys working one of those fancy-pants hydrolic arms to swap axles would take maybe a minute.

The hard part is hiding the 6-10 frame when the guards come-a-runnin'. I've been banned from 3 plants in metro Detroit already.