THE Falcon XR6 ute I bought new in 2004 developed a diff noise just past 61,000km. It's only done 63,000km and has been used as a workhorse, but Ford has washed its hands of the matter because it is out of warranty. Mechanics have told me the diffs are a regular problem. If so, surely Ford should repair or replace it. I have also been told the wheel bearings will go next and to put in an auto transmission cooler because there is a problem with the cooling cores in the radiator bursting. The auto then fills up with coolant. Ford knows about all these problems, so why doesn't it tell people who have brought BA Falcons and maybe go 50/50 on the cost of rectifying them?
THE diff is a regular problem. Ford was replacing diffs under warranty with new ones, then replacing them with rebuilt units in cars out of warranty. Try Ford again and press to have your diff replaced. Like you, I reckon Ford should come to the party when there are known problems.
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