Yet another failed axle bolt

[Buyer2021]

Sure, when the 'final remedy' is available, I'll jump on that.

Wait, maybe I should 'hedge' that a bit .... if I've still not suffered a failure I'll likely let that ride for a while to see what the 'feedback' is.

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[Snakebitten]

That makes a ton of sense, but if that were the issue, why didn't Ford just issue a different bolt and/or no thread locker? Perhaps the issue is that in order to avoid being overtorqued by the rotational play of the axle/hub splines, the bolt needs to be basically seized into the threads, BUT that condition prevents the bolt from adapting to some other stress which snaps them.

This is all rectally sourced speculation, so take it for what it's worth.

How do we know what the real difference is between the trucks that snap a bolt and the ones that don't is?

Speculation is all we have.

And I think it's obvious that I'm more than willing to participate! Speculate, that is.

I like my bolt and washer more than the one Ford crammed into my axle. So a little more than just speculation. I'm experimenting too. ?

 

[Buyer2021]

Speculation is all we have.

Ain't that the truth, on so many 'fronts' these days!

 

[Paul Neubauer]

You had a lot of influence on my own transition from WTH, and What-If........ to whatever. ?

It'll be so interesting to finally see what Ford's solution turns out to be.

I am curious why they don't just scrap the bolt idea and weld the two pieces together instead.

 

[FaaWrenchBndr]

I would like to see the statistics of the trucks that have broken bolts. I really wonder what the number of trucks are by engine. Is the power boost and the regenerative breaking creating more of a pressure on the hub and the shaft?

How many people that have the 5.0 have had a bolt break?

 

[amschind]

How do we know what the real difference is between the trucks that snap a bolt and the ones that don't is?

Speculation is all we have.

And I think it's obvious that I'm more than willing to participate! Speculate, that is.

I like my bolt and washer more than the one Ford crammed into my axle. So a little more than just speculation. I'm experimenting too. ?

I don't think that I saw where you used your own bolt. So did you just pull out the ford bolt and replace it with an identical dimension but higher quality material bolt?

 

[Buyer2021]

I would like to see the statistics of the trucks that have broken bolts. I really wonder what the number of trucks are by engine.

FWIW here's the latest summary from the other forum's admittedly small (statistically insignificant) sampling of bolt-break incidents

Make of that what you will.

Is the power boost and the regenerative breaking [sic] creating more of a pressure on the hub and the shaft?

I've speculated (forgive me!) on both forums about that, wondering aloud if the back-and-forth loading inherent in regenerative braking contributes to the rate of bolt-breakage which seems biased toward the PB.

Others have countered that it's likely there are more PB's with the 3/4-float axle than other engines, 'skewing' that small sample pool. Maybe so

One thing for sure: Ford isn't gonna publicize data to assuage that speculative curiosity!

 

[Snakebitten]

I don't think that I saw where you used your own bolt. So did you just pull out the ford bolt and replace it with an identical dimension but higher quality material bolt?

Bought a couple of different "Grade 8" (Metric 10.9) coated bolts.

Also looked up the typical torque settings for 12x1.75 bolts and only torqued to 84 ft lbs.

Unlike the Ford bolts, the machined threads are as clean on the bolts as the machined threads inside the axle are. You can thread the bolts in by hand. Just like you would think you should be able to. (try to thread the gnarly oem bolt by hand)

I currently have bolts from McMaster-Carr that have a black coating

There are some Dormans that are the same spec but a gold coating

On the driver's side I added a Bellville washer

On the passenger side I used a polymer washer.

Just 2 different approaches to "dampen" forces against the shear?

Anyways, as stated earlier, I removed them both at each oil change and look for any signs of fretting or deteriorating spline mating.

If you shear a bolt and don't notice it right away, you will SEE the evidence of fretting (red metallic dust) and the axle will no longer be stationary if you push/pull on it.

This last check, the axle and threads looked just like they did brand new.

Immaculate!

 

[bloodocean]

Hey all, I have a 2023 Powerboost with a broken axle bolt. My VIN is not covered by the recall, my build date was 2/6/23.

I would very much like for Ford to expand their recall coverage as I don't want a like-for-like replacement with another defective axle. I called their recall support line and opened a case, however they were emphatically unhelpful. They told me to file a complaint with the NHTSA, and they'd only expand the recall if they were forced to by the regulator.

I have since filed a complaint with NHTSA, and I noticed by looking in their database that a handful of other '23 owners are in the same boat: broken bolt and no recall coverage. If anyone out there has a '23 built after December 2022 and has a broken bolt, PLEASE file a complaint with NHTSA. Ford is hoping they get away leaving us high and dry.

I got a call from a NHTSA investigator less than 12 hours after filing my complaint. I am hoping they will find a way to motivate Ford to fix *all* of their defective axles.

 

[Snakebitten]

Hey all, I have a 2023 Powerboost with a broken axle bolt. My VIN is not covered by the recall, my build date was 2/6/23.

I would very much like for Ford to expand their recall coverage as I don't want a like-for-like replacement with another defective axle. I called their recall support line and opened a case, however they were emphatically unhelpful. They told me to file a complaint with the NHTSA, and they'd only expand the recall if they were forced to by the regulator.

I have since filed a complaint with NHTSA, and I noticed by looking in their database that a handful of other '23 owners are in the same boat: broken bolt and no recall coverage. If anyone out there has a '23 built after December 2022 and has a broken bolt, PLEASE file a complaint with NHTSA. Ford is hoping they get away leaving us high and dry.

I got a call from a NHTSA investigator less than 12 hours after filing my complaint. I am hoping they will find a way to motivate Ford to fix *all* of their defective axles.

You really aren't out of anything currently though. If any truck shears a bolt at this point, they are getting the same warranty repair regardless of recall.

 

[Buyer2021]

You really aren't out of anything currently though. If any truck shears a bolt at this point, they are getting the same warranty repair regardless of recall.

At least through the duration of the 5-yr / 60,000-mile powertrain warranty.

 

[bloodocean]

Redesigned parts are supposed to be hitting the streets 1Q25, what happens when i break my next bolt in late 2025? I get another serving of the garbage axles and earlier builds are getting the good ones?

 

[Snakebitten]

At least through the duration of the 5-yr / 60,000-mile powertrain warranty.

Yep.
And even if you don't have ESP and you are far beyond warranty, the whole assembly is something like $370?

I ain't happy about any potential weak points in my truck. But I'm hoping the potential sheared bolt is the worst problem I will ever face.

I'm more concerned about that CDF drum rearing its head after my warranty has expired.

 

[Snakebitten]

Redesigned parts are supposed to be hitting the streets 1Q25, what happens when i break my next bolt in late 2025? I get another serving of the garbage axles and earlier builds are getting the good ones?

You think Ford will have 2 different assemblies?

And you are sure that Ford's recall remedy is trouble-free?

 

[jhelrey]

I would like to see the statistics of the trucks that have broken bolts. I really wonder what the number of trucks are by engine. Is the power boost and the regenerative breaking creating more of a pressure on the hub and the shaft?

How many people that have the 5.0 have had a bolt break?

I did. If I recall, it was around 62K miles. I know it wasn't broke long due to tire rotations and the fact I could hear it.

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