Rear differential making noise and metal shavings in the fluid?

2016 FORD F-150

89,000 MILES • 6 CYL • TURBO • 4WD • AUTOMATIC

BRUCE BLANCH

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My truck was parked on side of the road and was struck from behind.
Bumper left side of bed, axel slightly bent, left rear tire and rim damaged. Got those items repaired or replaced. Drove it 5,000 miles and the rear differential started making terrible noise. Opened drain plug, lots of metal shavings on plug and in the oil. The insurance company claimed that the shop did not install axles correctly and that is the cause of the differential failing. I asked what evidence they have if that being the case and the adjuster said she didn’t have any evidence but that is the insurance company’s position.

Aug 17, 2022 at 7:54 AM

STRAILER

CERTIFIED EXPERT
53,854 POSTS

Yep, the insurance company assumes when a repair is done and if anything fails shortly after it must be the work that was done. You will need to fight them by removing the rear differential cover to see what the problem is. It could be a bent differential housing. Here is a video of the axle job being done on a similar truck. The process is the same on both with instructions below to show you how to inspect the gears and axles in the images below.

https://youtu.be/ytqXLSjHNm0

Check out the diagrams (below). Please let us know what you find. We are interested to see what it is.

Images (Click to enlarge)

Aug 17, 2022 at 5:50 PM

SQM

CERTIFIED EXPERT
6,383 POSTS

Hello,

If something was not installed properly, like if the shaft was not perfectly straight it will cause damages like metal shavings.

If there are components that are out of factory specifications or out of alignment, then this could happen.

Was there any frame damage? What about the suspension?

Let me know.

Aug 17, 2022 at 5:56 PM