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 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.

- Holly, MI, USA

Rear axle broke, pulled me off the highway, witness behind me said it was as though the rear end jumped up. My truck was totaled, and because I hit a culvert that did even more damage to the underside, I'm not sure that can tell it was a mechanical failure. I took pictures of the tire marks in the wet grass and the right tire path was about two feet wide as if the tires were sideways, this was before the culvert was hit. The left side tire tracks were of normal width. I did not run off the road, I was pulled off the road. It seemed as though I still had control of the steering but the rear end went its own way. Was extremely lucky that no injuries/fatalities occurred. I at this point cannot replace my truck that I bought new and treated like a baby. The truck was taken in at least four times early by my husband, and they were to notify the Ford company. My husband passed away in December 2000, and being as I know nothing about the problem that occurred only when going over 45, I.e., down the freeway as my husband often did, I assumed it was corrected, but so distraught that the mechanics of the truck was the last thing on my mind until the mechanical breakdown occurred. I think the Ford company should replace my defective vehicle with one of equal value, one owner, highway miles, and exceptional condition without any expense to me. I have a very high deductible, and will not be able to get a truck comparable with the money from the insurance company.

- Travelers Rest, SC, USA

Rear axel has cracked twice on my Ford F-150. I have not been in any accidents and have not bottomed out my car. There is no evidence of impact on my vehical.

- Anza, CA, USA

Master cylinder had to be replaced after going out twice/ABS light stayed on constantly. Dealer fixed brakes twice. Also, rear brake line failed, and consumer had no brakes. Had to use emergency brakes. Also, when truck was six months old rear axle broke.

- Marana, AZ, USA

Vehicle purchased new. Vehicle returned to dealer 18 days later due to problems. Metallic rattling and tinging noise coming from rear along with a fluttering, winde up noise coming from drive shaft. Other minor problems included wind noise(fixed once but still there), clunking in transmission(reprogrammed) and a vibration felt at 40-50 mph.dealer first replaced a complete drive shaft, then a complete rear axle assembly was replaced. Still have vibration while driving vehicle.

- Allen Park, MI, USA

While driving at 60 mph rear axle came off.

- Roscommon, MI, USA