Plug welds missing on axle tube

[Baja_bronco]

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???

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[swooshdave]

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???

I'm sure @Ford Motor Company will be along tomorrow to ask for your VIN...

No way to hit anything there. Is it threaded?

 

[Indarkness]

just for a reference. It’s a welded hole.

 

[BlueOvalBandit]

Did some jackwad drill it out? I don't see how a weld pops out and there's a little sliver.

 

[paxfish]

Never welded at all? Dammit! You're making me get under the truck again!

 

[BigMeatsBronco]

trail turn assist does this...the forces from one brake being locked up, and the other side unlocked, combine with the forces that want to cause axle wrap or pinion lift (twist) are too much for Dana spicers housing, this has happened to others as well and IMHO will continue to happen to others broncos in the future.

I predicted this would happened when I first read about trail turn assist before the Bronco was even released.
And I also suspect the spider gears get EXTREEM pressure and even deflection during TTA events.

in the OPs case the tube is twisting inside the cast iron center section., and likely sheared off the welds.

I've done this before on other vehicles when one axle housing mount was loose. the tube rotated inside the housing...it's an a fairly common thing.

my solution was to weld all the way around the joint.

 

[2023bronco]

my solution was to weld all the way around the joint.

Cast iron to steel. I had it done on my Chevelle's 12 bolt. I think nickel rod is the preferred method. Or tig N99.

 

[swooshdave]

trail turn assist does this...the forces from one brake being locked up, and the other side unlocked, combine with the forces that want to cause axle wrap or pinion lift (twist) are too much for Dana spicers housing, this has happened to others as well and IMHO will continue to happen to others broncos in the future.

Has it been reported on the forum before?

 

[BigMeatsBronco]

Has it been reported on the forum before?

yes

 

[Baja_bronco]

So we did some wheeling yesterday and this morning noticed gear oil from the rear end.

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???

So after further research it spun the axle tube. Two other have had the same issue.
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???

[/QUOTE

Did some jackwad drill it out? I don't see how a weld pops out and there's a little sliver.

the axel tube spun.

 

[Baja_bronco]

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

 

[thesocalexplorer]

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

Wow, that's absolute BS. Which dealer?

 

[Bmadda]

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

If they cover swamped alternators they will cover this. Dealer is trying to get out of it. Try somebody else if possible

 

[Ducati1098]

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

Show them this and contact Ford. Unless they can clearly prove abuse, this should be a warrantable concern. Off-roading alone does not void your warranty.

 

[cynicalrider]

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