Broken front axle at CV joint on my Bronco Badlands 4-Door 2.7L

[Evolkidbell]

Wish the OP could get back in here with some pics of the axle with the boot removed. I’d like to see what actually broke inside there. @Homebowlking

Agree. As someone who used to manufacture half-shafts, I would also be interested in what failed.

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[ZackDanger]

Is 4wd on these Broncos disengaged via vacuum like the ESOF on the F150? I hope not, but if so, it would be easy to switch the appropriate vacuum solenoid wire to ground using one of the upfitter switches. So when in 4Lo, flip the switch to disconnect the front axle - 2wd low! I've done this on my F150 and it works great.

I have no idea. Has there been any info out regarding auto locking hubs? With IFS it isn't really needed, since the front driveline doesn't move, the diff is in a fixed location. Something to find out, anyone know? I also see upgraded drivelines in the Ford aux parts list. Sounds like Ford is attempting to get out in front of the aftermarket upgrades.

The standard transfer case has front axle disconnect (ESOF?) and the advanced transfer case (models equipped with 4A) does not (TOD?).

Also there was a discussion about Integrated Wheel Ends (IWE)

I have no idea what any of this means.

 

[da_jokker]

Question...so what is the trail fix for this? I've seen videos of people partially removing things or whatever in order to be able to at least drive out of a trail.

So if a front CV joint goes out, what do you do?

Also, we seem to have 2 conflicting ideas going on. The first one is that you're supposed to stop, look ahead, and select a goat mode prior to actually hitting the terrain (this supposedly keeps your goat happy).

The second train of thought is that you approach pretty much everything in standard drive and only start to engage 4x4 features once you start slipping (which of course then can make your goat unhappy)

What's that saying, can't win for losing

 

[Dads_bronze_bronco]

If replacement parts are not immediately available, maybe the upgraded shafts from the accessory catalog are available?
If so see if you can talk them into installing the upgraded shafts as payment for your suffering

Now this here is the right line of thinking - something breaks or wears out, replace it with an upgrade!

 

[85_Ranger4x4]

Question...so what is the trail fix for this? I've seen videos of people partially removing things or whatever in order to be able to at least drive out of a trail.

So if a front CV joint goes out, what do you do?

In theory you could probably just remove it and limp out in 2wd. Pretty sure I could just pull a front shaft out of my F-150 provided I have the big socket on hand (yeah right) for the nut on the hub.

Most probably will just turn the radio up and limp it out with the shaft in place.

Extended time in the sticks like real overlanding you can almost not quite do in the US... probably not a bad idea to carry a spare shaft with tools to change (for anything)

 

[Arokcrwlr]

The standard transfer case has front axle disconnect (ESOF?) and the advanced transfer case (models equipped with 4A) does not (TOD?).

Also there was a discussion about Integrated Wheel Ends (IWE)

I have no idea what any of this means.

Thanks for the info!

I'm not sure what "Front Axle Disconnect" means, but if the standard transfer case has ESOF/IWEs, then 4WD is most likely engaged/disengaged via vacuum. Which means there's a vacuum solenoid (more correctly a IWE solenoid), so you can add a switch to the wire that connects to the transfer case control module and control vacuum to the IWEs to disconnect them while in 4Lo (or 4Hi but what's the point?).

 

[NatureMan]

Thanks for the info!

I'm not sure what "Front Axle Disconnect" means, but if the standard transfer case has ESOF/IWEs, then 4WD is most likely engaged/disengaged via vacuum. Which means there's a vacuum solenoid (more correctly a IWE solenoid), so you can add a switch to the wire that connects to the transfer case control module and control vacuum to the IWEs to disconnect them while in 4Lo (or 4Hi but what's the point?).

I’m not sure on the bronco, but 2021 f-150 switched to electric actuated instead of vacuum.

 

[Arokcrwlr]

I’m not sure on the bronco, but 2021 f-150 switched to electric actuated instead of vacuum.

I hope that's the case - I never liked the vacuum system as it was prone to have issues including the vacuum line getting damaged offroad.

 

[dgorsett]

The standard transfer case has front axle disconnect (ESOF?) and the advanced transfer case (models equipped with 4A) does not (TOD?).

Also there was a discussion about Integrated Wheel Ends (IWE)

I have no idea what any of this means.

Come on Zack...you know everything!! Or at least where to find it.

By putting puzzle pieces together it seems: Models with Auto TC and certain BB and OBX models w/4.27 axles do not have FAD. Others with Base TC have FAD.

The FAD seems to be at the differential not at the wheel ends (IWE). I say this because the lube capacity in the Owners manual is different for those w/wo FAD. Weak evidence I know, but evidence.

 

[da_jokker]

In theory you could probably just remove it and limp out in 2wd. Pretty sure I could just pull a front shaft out of my F-150 provided I have the big socket on hand (yeah right) for the nut on the hub.

Most probably will just turn the radio up and limp it out with the shaft in place.

Extended time in the sticks like real overlanding you can almost not quite do in the US... probably not a bad idea to carry a spare shaft with tools to change (for anything)

It's been a long time since I've swapped out a CV axle, and it was on a car, but you had to be very careful pulling the axle out from the transmission and sliding in the new one without things misaligning or fluid leaking out.

So with things like this, can you really just pull a CV axle out and drive it with a big hole in your diff? (Maybe plug it with something to keep the dirt out)

 

[85_Ranger4x4]

It's been a long time since I've swapped out a CV axle, and it was on a car, but you had to be very careful pulling the axle out from the transmission and sliding in the new one without things misaligning or fluid leaking out.

So with things like this, can you really just pull a CV axle out and drive it with a big hole in your diff? (Maybe plug it with something to keep the dirt out)

My F-150 has big flanges on each side of the front diff the half shafts bolt to. It's the only thing with cv shafts I have played with.

 

[gemask]

It's been a long time since I've swapped out a CV axle, and it was on a car, but you had to be very careful pulling the axle out from the transmission and sliding in the new one without things misaligning or fluid leaking out.

So with things like this, can you really just pull a CV axle out and drive it with a big hole in your diff? (Maybe plug it with something to keep the dirt out)

If the Front diff is like what I have in my F150, basically the output on the side of the diff has a flange that the CV axle bolts to and the diff is still sealed without the CV attached.

 

[Bronco4]

Why shouldn’t they? Hope so. I have driven millions of miles beat the crap out of vehicles and had minimum problems. Most nothing like a broken drivetrain with 270 miles.

No one should be able to break this truck this easy. Not good…

Mr. Nice you might want to rethink your reservation.

 

[Roll Sound]

Question...so what is the trail fix for this? I've seen videos of people partially removing things or whatever in order to be able to at least drive out of a trail.

So if a front CV joint goes out, what do you do?

Also, we seem to have 2 conflicting ideas going on. The first one is that you're supposed to stop, look ahead, and select a goat mode prior to actually hitting the terrain (this supposedly keeps your goat happy).

The second train of thought is that you approach pretty much everything in standard drive and only start to engage 4x4 features once you start slipping (which of course then can make your goat unhappy)

What's that saying, can't win for losing

Most guys that I wheel with carry spare axles, welders, and a bunch of spare parts. We once broke a rear axle on a jeep and our tire and wheel came off. We had to cram it back in, put grease on the sidewall of the tire, grease up our high lift jack, and ratchet strap it horizontally to hold in the tire! We had to drive about 4 miles at about a mile an hour to where our buddy could meet us with a flatbed trailer. Had to tow it out. You do what you can on a trail, and hope you have friends like these. And plenty of beer.

 

[Mr. Nice]

Mr. Nice you might want to rethink your reservation.

Not at all. Super cool Mall Crawler just like most every Jeep I see.
But without the death wobble...

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