Broken front axle tube

[Texpedition45]

Has anyone else had this problem? I'm 2 for 2 in the last 6 months. The first one, it appeared to he a stress break near the mounting point. On this one, it appears to be a stress break, again, all the way around adjacent to the differential.

Did some google fu, and it seems there's quite a few threads on different F150 forums, from different years (10th and 11th gen F150's ).

Has anyone had this problem with their expedition?

 

[docraymund]

Check your 4wd system. It might be engaged all the time causing torsional stress on the axle tube especially when driven on bumps and potholes.

 

[Texpedition45]

From what I read over the last few days, I'm thinking the same thing. Even if it's engaging for a sec at WOT, the shock load must be enough to eventually cause the tube to fatigue and crack.

I'll post pics of the last break, and the current one.

 

[reece146]

I'd like to see the pictures.

Other makes can have this issue also - but from an off-road usage point of view. I went as far as to design a replacement for a different vehicle in fabricated steel plate but ended up changing platforms instead.

 

[Texpedition45]

Sorry for the late reply, and excuse the pics, it's the best I could do at the moment. The pics below are from the most recent issue before I dropped off the Expy today:

 

[Texpedition45]

And these are from the prior instance a few months ago:

 

[Texpedition45]

Well got it back today. Sinxe I have the brown wire mod, I'm going to keep the switch on "off" from here on out until I have to use 4wd.

I will update as it goes. Has anyone replaced the axle breather tube aand moved it to a higher position in the engine bay?