Front Diff and weird rattle - WTF

So it seems like the Front Differential issue has arisen at 35,700 miles (just shy of the bumper to bumper warranty expiring).

Under varied acceleration circumstances I would get a sound out of the front end that sounded like a cowling was loose - a flapping sound (no not a FAPPING sound). It would go away as speed increased or decreased. very odd.

Since I was right at the end of the warranty period I brought it in to have it looked at and the tech rides with me so he can hear it.

"Hmmm he says - this is the third one this month" - WTF Seriously?

Gets it up on a lift and tells me that the front end seems loose and he thinks the noise is coming from the front diff. I read all over this site that this is a common problem on the 2011+ but with so many of us having issues why is there no recall? It seems like it's a mater of WHEN this problem hits you not IF.

 

Recalls are for life threatening issues. This isn't one of them.
Tsb on the other hand, this would fall under. tsb is just under recal, nothing life threatening. Nothing big enough to cause a riot over. Tsb is one of those things they know is wrong, but wait till you find out to change it. If you don't notice, they won't change it, won't cost them money either

 

I'd say get it fixed, get it back and see if it still happens. Take care of it before your warranty runs out

 

There was a similar noise/problem in a different thread. It was the front fender liners loose and hitting the fenders/frames

 

does the noise go away in 4x4?

If so its your front diff driver side CV output... the crappy designed needle bearing. They should replace it but its not going to fix it. Just be better off buying the ECGS bushing and having them put it in for you.

 

So I bring it in and they tell me the front diff is shot they ordered parts and I won't get the truck back until THURSDAY (it's Monday). No loaner, no nothing. Seriously sucks

 

Following....

 

just curious, are you at stock height?

 

Yes stock height and TRD O/R with "standard" rear Leaf springs

Got it back and it is much better. Still a bit of noise under acceleration but much much quieter than before and the front end is a lot tighter. I guess that the looseness was gradual and I would not have noticed the front end getting sloppy across 2 years.

Drivetrain warranty is 5/60 but it might make sense to have your stealer check your front diff next time it goes in for svc