Update: Rear Axle Tube - 1200 Miles Warranty Covered

[kgolive]

I am revising this post to clarify Ford is replacing the axle under warranty. The axle tube and plug weld issue is a warranty gray area and can go either way.

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[fordbroncowildtrak2023]

Perfect time for a Dana 60 install!
Just kidding. Bummer for you, OP.
These plug welds now seem to be an area of concern.

 

[kgolive]

I’m on the fence with what I want to do. Assuming warranty doesn’t cover it, what kind of options are available so I’m not doing this all over again in a few months? I wasn’t even driving the truck hard. I was hard on my 4Runner and never had a single problem with it and it was supercharged.

 

[Aztec1382]

Which axle and what gearing

 

[kgolive]

4.46

 

[Farmerjim47933]

Perfect time for a Dana 60 install!
Just kidding. Bummer for you, OP.
These plug welds now seem to be an area of concern.

i am wondering if the 4 link suspension during a high or low obstacle twist of axle vs body is causing a twisting of the left tube vs the right tube and the weak points are the plug welds or now the tubes themselves ,easy to duplicate in shop by removing 1 of the 4 link end bolts and lift 1 side to see if hole still lines up

 

[kgolive]

i am wondering if the 4 link suspension during a high or low obstacle twist of axle vs body is causing a twisting of the left tube vs the right tube and the weak points are the plug welds or now the tubes themselves ,easy to duplicate in shop by removing 1 of the 4 link end bolts and lift 1 side to see if hole still lines up

That’s exactly what I was thinking. I can’t be the only one this is happening to

 

[colbert]

Should the Kraken be summoned? Not much different than ADMs on Reservation Holders.
37s are the new 33s and are not the reason this happened. Burden of proof lay with the manufacture.

 

[Bmadda]

I have been on 37s since 1200 miles, have wheeled locally, and done Bronco safari in Moab...and some tough trails...zero issues. I leave rear locker on when I leave pavement and never shut it off till we hit pavement again (and one time I forgot)...this simply shouldn't happen plain and simple

 

[Tricky Dick]

Have you used TTA? The last guy that broke his plug welds suspected it was TTA.

 

[kgolive]

I have been on 37s since 1200 miles, have wheeled locally, and done Bronco safari in Moab...and some tough trails...zero issues. I leave rear locker on when I leave pavement and never shut it off till we hit pavement again (and one time I forgot)...this simply shouldn't happen plain and simple

I’ve had a few other people say the same and it just doesn’t make sense why this happened. Here’s some trail photos. Nothing a Prius couldn’t handle.

 

[kgolive]

Have you used TTA? The last guy that broke his plug welds suspected it was TTA.

No I don’t even know why anyone would find that feature useful. I’m not doing switchbacks on black bear pass

 

[Farmerjim47933]

Should the Kraken be summoned? Not much different than ADMs on Reservation Holders.
37s are the new 33s and are not the reason this happened. Burden of proof lay with the manufacture.

I agree 37's are not the problem . . Plug weld should never shear. They are not doing something correct ,not enough heat ,dirty oily metal ,wrong wire ,ect .But I still say it'a binding in suspension geometry.

 

[Felix808]

I’ve had a few other people say the same and it just doesn’t make sense why this happened. Here’s some trail photos. Nothing a Prius couldn’t handle.

Hey is that Pilot Rock?
No I think it's Dana quality control issues.

 

[kgolive]

Hey is that Pilot Rock?

Yes and I’ve done this trail dozens of times in my 4Runner and never broke a sweat much less an axle

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