2022 F150 Rear Axle exploded... Ford tech said "3rd one this week"

[Ed21]

Axles just don't "blow up." The design elements are so well known. This had to be a manufacturing defect. If it did have that fractured bolt, a misalignment would eventually occur as stress was moved around with fewer bolts to carry the load... and there you are: a failure... The alignment ot gears in the differential is critical...

3rd one this week would be cause for concern.

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[Snakebitten]

Mechanics say stuff like that.

 

[slanker7]

Well, they do have a recall out on other models...I don't think he was making it up

 

[powerboatr]

i would like to see pics of inside the pumpkin

if possible ..only because my gear brain is active

dam the luck
hope they get you sorted out

 

[Snakebitten]

I just meant I'm sceptical that one mechanic saw 3 "blown up" F150 rear axles in a week.

He could very well have seen 3 F150's with the broken bolt issue

 

[slanker7]

Could you post the work description and part #s after you get the truck back? Very interested to see what was involved.

 

[Golf Cart Wizard]

I just meant I'm sceptical that one mechanic saw 3 "blown up" F150 rear axles in a week.

He could very well have seen 3 F150's with the broken bolt issue

You never know, strange things seem to happen in mechanic shops. I'll go a year without seeing a particular problem and then BAM! I'll literally get 3 the same week. So I'll then stock up on that part just for it to sit on the shelf another year. So it goes

 

[slanker7]

They were closed... left the key under the mat. Not much info here.

 

[Snakebitten]

That's the ordinary repair of the broken axle bolt on the Max Tow axle.
But yours definitely had a bigger problem than just a broken bolt.

Surprised it didn't damage something beyond the axle itself if it lost drive.

 

[Buyer2021]

So is it possible that if the Max Tow axle bolt broke, and you never discovered it, and just went on for many thousands of miles......

Couldn't that axle eventually move away from or toward the pumpkin enough to "explode", so to speak, the differential?

Yes. There have been a few other reports of the axle-bolt failing and as a result of continued driving the axle-shaft migrates inboard until the splines at the outboard hub-end strip due to inadequate engagement.

So far I've not seen reports of damage at the differential as a result of this. It seems the hub-end splines strip before things move far enough to cause problems in the differential.

Mechanics say stuff like that.

For sure, just like owners say stuff like "rear axle exploded" (everyone loves hyperbole)
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Yep, the posted work order shows axle assembly replacement just like it would for a warranty repair of a failed Max Tow axle bolt. Unfortunately, this at the owner's expense because it's not within the Ford-identified CSP coverage nor within powertrain warranty miles .

I'd definitely preserve that documentation in case Ford expands the CSP coverage or a full-blown recall is issued with a later offer of reimbursement for affected owners. ?

Can't help but note that the cost of this repair would go a long way toward paying for an ESP contract.

 

[slanker7]

At $1,200 I'm possibly still ahead of the game for the extended warranty for 100,000 miles. I'll hit 100,000 by February-March of 2024. I got tired of paying for warranties and never using them. Might come back to bite me....

 

[Buyer2021]

Might come back to bite me....

I sincerely hope not, wishing the best for you.

BTW, maybe I missed it in the thread but what engine do you have (3.5EB, 5.0, PB)? Just curious.

 

[HammaMan]

Yes. There have been a few other reports of the axle-bolt failing and as a result of continued driving the axle-shaft migrates inboard until the splines at the outboard hub-end strip due to inadequate engagement.

This is the first thing that came to mind. Failed bolt, axle migrated in until remaining spline engagement was such it could no longer take the torque and twisted em to nothing.

Ford best be eating this repair due to known design flaw.

 

[Snakebitten]

Ford best be eating this repair due to known design flaw.

Totally agree!
Where's that Ford bot now?

What's aggravating is that there ARE people with Ford (manufacturer) that have the authority to approve this and would. But that's little help if neither the dealership or the customer has a known avenue to get something like this in front of those folks.

In my vocabulary it's called goodwill. And this is exactly the kind of circumstance you spend some of that goodwill budget.

Any Gen14 Max Tow truck should qualify for obvious reasons.

 

[Snakebitten]

By the way, this is why I have them on hand. If I ever discover the broken bolt, and the dealership doesn't have the axle on hand for the repair, I'm drilling it out and rebolting while I wait.
Or at least that's one strategy.

I've been tempted to just swap them out pre-emptively too.

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