Plug welds stock suspension

[GrumpyVet]

I’ve noticed some posts here for plug welds failing mostly on modded suspension setups so I decided to crawl under my stock suspension Badlands and take a look. My opinion is these welds are about to completely break at any moment looks as if the whole housing was dirty or rusted when they welded these. I’m no expert, but with these cracks I would think water can get in and oil can escape.

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[PWillette]

I'd have to agree with you...those look like shit. In my mind the rusting indicates a lack of penetration. That first picture doesn't look good at all.

 

[Boreal]

@GrumpyVet inspired me.

Original Bilsteins with upgraded springs. Everything else suspension and wheel wise is OEM. I’d say that the penetration/fill was a little lacking.

 

[badbronc4x4]

Im curious the ones you actually have issues with or bad looking plug welds are they on your Drivers Side? There has been more and more plug welds more on the drivers side that have been coming up. Another gentleman has the same issue with only 1200 miles on his and was just denied by Ford as well.

 

[Combustion_King]

Gonna go check now see what i got going on.

 

[flip]

Those are some pitiful plug welds. Wonder if it's robotic or human welder because I'd fire myself if I couldn't burn turds in better than those. Damn near makes me want to tear the diff apart and inspect the inside of the tube to see if even bit or just enough to fill up the hole. Guess a guy could always drill most of it out and dump a new glob in there then weld around the center section/tube interface to make sure.

 

[GrumpyVet]

Im curious the ones you actually have issues with or bad looking plug welds are they on your Drivers Side? There has been more and more plug welds more on the drivers side that have been coming up. Another gentleman has the same issue with only 1200 miles on his and was just denied by Ford as well.

Yup drivers side looks worse. I have a 2021 with around 9k miles. Guessing at some point Ford will have to address this.

 

[SubmarineNuke]

Yup drivers side looks worse. I have a 2021 with around 9k miles. Guessing at some point Ford will have to address this.

Will they though? Or will the Ford account just ask for your VIN and dealer and leave it at that???

 

[PWillette]

So I had to crawl under...here's mine for comparison

I’ve noticed some posts here for plug welds failing mostly on modded suspension setups so I decided to crawl under my stock suspension Badlands and take a look. My opinion is these welds are about to completely break at any moment looks as if the whole housing was dirty or rusted when they welded these. I’m no expert, but with these cracks I would think water can get in and oil can escape.

So I had to crawl under and get a look at mine...here's for comparison...

 

[Silver-Bolt]

The rust is an indicator that there is an empty void under the weld. Not good at all.

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