Plug welds missing on axle tube

[flip]

Wow, gravy repair. No idea why they wouldn't want to do this. May need to get the assembly which could be on back order but it really shouldn't be driven until it's fixed propperly.

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[indio22]

UPDATE!!!!
The dealer is saying they won’t cover it because I took it off-road. This is gonna turn into a shit show.

Seems a defect to me, leastways my old 4x4s have years of off-roading without spinning an axle tube. And I'm talking some mediocre CJ axles.

Note to self: if my future Bronco ever has an issue, hand on the bible "sir I never off-roaded".

 

[Baja_bronco]

Wow, gravy repair. No idea why they wouldn't want to do this. May need to get the assembly which could be on back order but it really shouldn't be driven until it's fixed propperly.

It won’t. If they decide not to fix it, it will get a fabricated housing.

 

[Felix808]

Would there be any issues just welding in a new plug? How about running a bead or 2 on the tube to housing union

 

[Deleted User 5719102]

So we did some wheeling yesterday and this morning noticed gear oil from the rear end. Well on a creeper with a flashlight I noticed one of the plug welds are missing on the axel tube. How does one explain this???

Based on this picture, the axle tube looks to have moved out from the diff housing about a 1/4" from when it spun loose.

 

[Wildfire1]

Has there been a mods added to the rear suspension ?

 

[Donkeygyrl]

It looks a piece of welding wire is in there ?

 

[Baja_bronco]

Well the Dana 60 gets ordered tomorrow.

Would there be any issues just welding in a new plug? How about running a bead or 2 on the tube to housing union

The dealer is claiming the gears and bearings are compromised but without checking myself I don’t know. But yes would be not to bad to fix.

 

[Baja_bronco]

So the dealer offered to submit for warranty but if denied I would have to pay out of pocket. The new Dana 60 is back ordered right now. So I’ll have to fix this one till back in stock.

Look at the welds in it. I’ve attached more pictures and you can see they are not great.

 

[sgraing1]

Dana aint the company it used to be. By a long shot.

 

[Bmadda]

Well the Dana 60 gets ordered tomorrow.

The dealer is claiming the gears and bearings are compromised but without checking myself I don’t know. But yes would be not to bad to fix.

A piece of weld metal coulda fallen inside the diff and trashed everything. Would probably be best to replace the whole assembly.

 

[Baja_bronco]

Has there been a mods added to the rear suspension ?

It has the Baja kit arms coil overs and bypass

 

[Yeti-X]

Unfortunately I'm guessing you are running running bigger than stock tires, probably wheel spacers, and aftermarket suspension all which will add substantial extra strain on the the axle and that would be easy to prove by any technician so I would say warranty is out the window on this one. But like Big Meats said get it back in place weld all around the flange on both sides of the housing. We did it on pull trucks for years before we ever even used it for added strength

 

[Wildfire1]

It has the Baja kit arms coil overs and bypass

It’s a nice set up. I used to be a service manage at a big dealership and that repair would have been rejected if warranty was involved due To those parts not being engineered by the manufacture and possible caused the axel tube to fail. As for seeing wire in the weld thats normal. Mig welding is a wire feed system and Ive seem many components welded with wire stuck to them.
I hope you get a warranty claim but be prepared. its on you now to prove those cool suspension components didn’t cause the failure. Good luck. .

 

[Donkeygyrl]

What ever happened to lift me baby,now its voiding warranty?

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