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I have owned my 2008 F450 for 2 years and have had the rear end fixed and replaced 8 times. It lasts approx 250 miles then the bearings burn up and I haven't even towed with it. The Ford engineer can't figure it out. They replaced the drive shaft 3 times also. The truck has spent more time in the shop than on the road, Ford refused to buy back the truck and I have a lawyer on them for the lemon law...Is there anyone else having this problem??  

8 times.....  something is wrong with the housing... they should have put a complete rear end in it... after the first time.. they are available...

rebuilding a rear end after a bearing failure... you have to get every bit of metal debris out of the rear end...   you also have to put in several strong magnets... wedged into the bottom inside of the case...  this pulls all of the metal particles out of suspension...

i have run into a bunch of rear ends that had the cover gasket changed... and the tech used a high speed grinder to clean the gasket surface... this spread grinding particles through the rear end housing..

i would also take it back to a different ford dealer... after 8 trys... its time for the factory ford rep to take charge...

you should also send copys of your receipts for the repairs to ford... they had to pay for each one.... and the dealer should have just replaced the rear end after the first failure..   so the dealership is working the system...  

They changed the housing 2 rebuilds ago but didn't change the carrier. They have been guided by the hot line and a field engineer. I have called several times to get the regional on the phone but no one gices me his number or info. The owner of the dealership said he is aware of the issue. This is a $66,000 truck that sits there. So anyone else who has a whine from 35-40 beware. Luckly I am under warrenty and had purchase an extened warrenty but get this the rental is good for 10 days for each issue....so I have no vehicle. No one cares about that.  

call a different dealership....


ford extended warrantees are good at every dealership...


got any lawyer friends...

look up your local ford zone office...  place a call to them...

find out how much a complete rear end is...

since you are not doing anything...   stop by the show room... walk around with the salesmen....   hang out with the general manager...   make sure they know why you are there... i cannot drive my 66 thousand dollar truck...  as your techs keep patching the rear end... instead of replacing it...

is your truck at the dealership????  torn down... waiting for parts????  or just sitting off to the side.. complete.....

when i was a kid...  mom bought a 60 lincoln continental ...  we went through 21 power steering cylinders...   and had to be towed back to the dealership every time..... seems the first mechanic replaced one of the parts with a 59 part... or thats what they told mom when they finally figured out what was wrong...  it was a little longer or a little shorter... what ever it was... if you turned the wheel to park... it would blow the top out of the power cylinder...  i can feel your  pain..  the self adjusters also did not work quite rite...  it took my brother to find that problem..   the cables that held the adjuster arm up was a bit too short... held the adjuster lever above center on the star wheel... so when it lifted... it did not catch the star wheel..  while on vacation in utah.. pulling a trailer.. going down some gorge... we lost the brakes... only had the transmission to keep us from speeding out of control...   the brakes had been in for service several times...      one tech even took off the self adjusters... threw them in the trash...   that just does not work with a 5,000 pound car with drum brakes..

your problem is starting to sound like it is mechanic error... they are lacking some tool or have read the numbers wrong...
perhaps they are setting the pinion pre load to foot pounds instead of INCH pound of torque to turn the pinion with the ring gear out..      i used manage the cylinder head department in a local engine rebuilder...  one of the engines we specialized in was ford tractor motors..  the tractor motor manual grew legs and walked out the door somehow...  everything was easy to set up by memory.. except .. no body could remember the cylinder head torque...  i got on the phone to the local ford tractor dealer... got to the service department.. ask them the question.  they came back and said  some number that sounded too high..  my boss who was assembling the motor... ask what they had said..  when i told him... he walked away and over to the motor.. i told him to wait...  i did not think that was the right number.. but  he was sure... he twisted off 2 head bolts before he gave up..   after i got that motor and a few more finished.. i walked out..

being a noisy mechanic and usually the supervisor in most of the shops i have worked at.. i have taken the torque wrenched out of several techs hands .. when they ask what the torque setting was for a car... and spun the torque wrench up to that setting... without pulling the torque in stages...  

i have a friend who worked at a ford dealer for over 10 years... they fired him...  he repaired the cars by diagnosing and changing just the parts that were bad...   they kept the techs who spend days working on cars...

one tech there spent a week on a hybrid car... trying to find out why it shut off at stop signs.. a whole week... billed to ford.  when there was NOTHING wrong with the car... except the owner had not read the manual ... or had been informed by the salesmen on how the car worked..  i have a feeling thats why so many dealerships were closed over the last few months... jamming the factory for thousands of dollars of unneeded repairs...  

on ford taurus models of the past few years...  they would set an egr code... might be a P0401.. every taurus needs a new DPFE valve and a EGR solenoid valve..  about 100 bucks retail... 15 minutes flat rate to install.. if you have the tools handy.. you can do it in 5 minutes on a hot motor..    nope... they charge customers 600 bucks to do it.. and throw in a whole pile of other repairs... that are not needed.. ford build the taurus fairly well...

several dealers quoted a friend of mine... 600 to replace his heater core in his explorer...  the flat rate is 30 minutes.. i did it in 10...  why....  i just cannot understand ... why dealers cannot understand why people don't want to take their cars to them..

but then some mechanics area just as bad...

i just got a call... a friend of one of my customers...  a ford 460 in his 30 foot boat...  he took it to a marine mechanic.. to rebuild the motor...  it had 32 pounds of compression and a noisy rod...    $8,700 bucks later..   when the job was finished.. the marine mechanic.. said.. oh yea.. you need a new short block...   i just did the heads...    more please..

do you have any junk yards near by... where they might have one of these super trucks.. that you could buy a rear end from...

i bet that if it went bad in 30 days.. they would give you another complete rear end...  

so .. now you understand.. while i am off work... i spend so many hours trying to help people...  with just my fingers...  and my 30 years of experience...