Glad you found your problem onefordgt.
If you're still around here, did you ever feel a steering wheel vibration [which may be related to that play] or did you just have the brake concern.
Is this amount of play considered normal? I've got the same. Also, when I was setting the torque to 150 lbs, I kinda rocked the car and I could hear a clanking noise coming from the front center of the car. I can reproduce it but I have no idea what it could be, since the car was on the ground...
Since Ford will have all work done thru a dealer, go to your dealer and just say you have a 'vibration' problem. Let them troubleshoot it and take ownership of it [or tell you "they all do that"]. Their feedback will determine what follows. Ford Canada doesn't know what the root problem is...
My 15 V6 had stock 3.15's, had the problem, worked on for over 5 months & I'm now starting arbitration with our Auto Manufacturers Arbitration Program up here. Process can take a couple of months, but it will be interesting to see how that goes!
Well... in my dealer's defence, they wanted to try a 1 piece driveshaft but Ford Canada said "you put it on, you pay for it & cover any possible problems down the road". Guess who didn't get a 1 piece driveshaft!
They also wanted to try an outside driveshaft balancing shop...
Ford said nope.
My...
I've still got the vibration. Ford Canada engineering came on the 2nd & drove the car, felt the vibration [really? it's been 5 months now], they are going to discuss with Dearborn office during a regularly scheduled get together this week. Outcome, who knows?
Are you dealing directly with...
This was exactly my scenario up to the point of the differential replacement, which was completed today. Unlike yours, my vibration is still there. Kinda gives pause to the whole "it's the differential" thought process. Dealership is at a complete loss as to what to do now. Ford has given them...
Wow, I hope that's not an indication of how long mine will take. I was told delivery was to be expected last week. Still nothing so far. Came back from a trip to Niagara Falls today and was gritting my teeth by the time I got home & it's only an hour drive!