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Wheel came off from slight swerve on flat pavement

Broncohio

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vehicle: bronco badlands sasquatch lux 2023
reserved date: 7/20/2020
build date/week: 4/13/2023
picked up: 05/11/2023

I picked up my bronco from Stephens auto center on Thursday May 11, 2023 and drove it ~300 miles back to Ohio. Over the next 2 weeks I babied my bronco and added on another ~400 miles, refusing to even take the doors/top off until heavy rain to verify it was sealed good. I never even used any of the hero switches just to see how it works on country service gravel/dirt roads.

(shout out to Stephens Auto Center on excellent service and getting me in and out the door quickly with my new Bronco!)

May 26th at approximately 2:30 am, was on a multi-lane road traveling roughly 50 mph, noticed animal on right shoulder of the road, switched lanes to give more room. Upon getting closer the animal decided to cross the road and I swerved back into the right hand lane and felt like instantly had a flat tire. multiple warning sensors came out the dash: antilock break fault, hill start assist warning, and pre-collision assist not available. The swerve was very gradual/soft compared to what I've had to do in past vehicles to avoid incidents and for this low mileage/new vehicle to handle itself like that just worries me that there is more to come in the future. I am grateful, that I was not on a high speed road and there was no traffic in the other lanes/passing vehicles/merging/etc when this took place.

Due to being on the road, and it in the middle of the night, saw a parking lot roughly 200 yards ahead in which I drove to very slow with emergency hazards on. when turning into the parking lot, felt like power steering was out and due to going ~10 mph it turned very wide and made some thudding noises. Once I was safely off the road, got out to inspect the damage and found my wheel basically came off... which I'd assume happened during the turn process as it just handled like a low aired tired the rest of the time.

notified non-emergency local police, however I didn't realize they don't do anything for non accidents and due to me getting it off the road for them, they stated they didn't need to tow it or fill out an incident report. notified insurance for roadside service, and they estimated ~45 minutes. There is a Ford garage roughly 10 minutes from there in which the tow truck took me to and dropped me off at roughly 4:00 AM. Family then came out to pick me up at the dealership. I returned later that day during business hours to hand over my keys and see what was the next step. They never offered me a loaner/rental/etc and basically said anything of this nature is under warranty in the first ~60 days I believe and it'll be repaired free of charge.

As of Friday 6/16 they updated me that they are waiting on a backordered part, the stabilizer bar.

Everyone jokes, asking if the animal was worth my vehicle. Based on how easily it came apart, it was bound to happen sooner or later.

I'm at a loss what I'm suppose to do, just wait for the vehicle to be repaired and go back to driving it? This was a vehicle I've waited nearly 3 years for and spent a small fortune on. I wanted to fully customize it, but I'm worried any/all customizations would void future warranties and whose to say more issues aren't around the corner. because they fixed the one side, will this happen to the passenger side/rear wheels next? and no matter what you do, a vehicle repaired is never new. I'm terrified to even attempt any offroad obstacle in it just seeing how it handled on flat pavement.

I've called Stephens auto center just to inform them and ask if they had a number for me to get in touch with ford, they directed me to the same customer service line on the website. (1 800 392 3673) I have called them 3 times and always get disconnected or passed around/waiting on hold and never get to talk to anyone.
Ford Bronco Wheel came off from slight swerve on flat pavement bronco04
Ford Bronco Wheel came off from slight swerve on flat pavement bronco05
Ford Bronco Wheel came off from slight swerve on flat pavement bronco06
Ford Bronco Wheel came off from slight swerve on flat pavement bronco01
Ford Bronco Wheel came off from slight swerve on flat pavement bronco02
Ford Bronco Wheel came off from slight swerve on flat pavement bronco03


I just wanted to bring awareness to this, see if anyone has any input on why/how it happened and if there is anything to do moving forward, otherwise thanks for letting me vent.
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Lcubed

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definitely doesn't look like the primary cause was the SBD.

that's a pretty impressive failure/fracture of the casting
 

rtaylor

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TrailRaider

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Definitely a defective casting. I would ask them to scrutinize the passenger side casting as well.
Replacement parts will likely be made well after the original ones so I would not be too concerned with getting replacements that would fail the same way. That type of break will cause LOTS of the other items in the area to be rendered useless, and many items will need to be replaced. The sway bar assembly has always been in short supply, judging by how few (comparatively) Badland have been produced. As long as the servicing dealer has competent techs, I would guess the risk of any repeat or similar failure is very low. My $.02 of course.
 

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SWLABRONCO

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Dang. The man upstairs was looking out for you. Glad to hear you're OK. Now I'm going to crawl under my wife's bronco and inspect it. Hope everything works out. Like Trailrader said the dealership should get you fixed up. Good luck.
 

JT58Bronc

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Wow something in the casting of the aluminum failed. Or severe overload and stress as a result of the steering maneuver. Has to be an isolated case. Glad you are alright and it was not a roll over or anything like that.
 

mcinfantry

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Wow. I’d reach out to Ford and ask for an extended Ford warranty for that mess. Maybe even see if they can send a new Bronco.
Damn, you have an issue and they just send a whole new bronco?
That would be a great deal!
And glad to know that’s how it works
 

flip

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Kinda wondered how big that void was in the knuckle, wow. Glad no one was hurt and kind of surprised we haven't seen others with similar breaks from hard off-roading. I guess it's good there aren't, sucks OP had to be the one with the problem, especially in that situation.
 

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Sweetair

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Geeze, fortunate that no further damage happened to you or the Bronco. I am hoping for a speedy repair for you.
 

BAUS67

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Kinda wondered how big that void was in the knuckle, wow. Glad no one was hurt and kind of surprised we haven't seen others with similar breaks from hard off-roading. I guess it's good there aren't, sucks OP had to be the one with the problem, especially in that situation.

Ford knuckles are hollow. I found this out not long ago and was shocked had to do the double take when I found out. My guess to save weight. :)
 

Silver-Bolt

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Yowza! I haven't seen an upright/knuckle failure happen without some sort of impact. You were very lucky that you got it slowed down before it completely let go. Had you still been at 50mph you likely would have ended up on your top. The break looks very clean. Most casting fractures have a very jagged appearance. The photo almost looks like it was sawed through. Crazy. I wonder where they source those?
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