I know this is more suitable for the Super Duty or the Excursion forum but I spend 95% of my time in here. So here it is.

Some of you know that I have been chasing a vibration for a long time. Last fall I replaced all the rear bearings and seals. That didn't do it. So this spring I tackled the front end. Last week I installed new XRF ball joints, XRF tie rod, XRF drag link, Red Head steering box, new greaseable front axle u-joints, and adjustable camber/caster bushings. Top all that off with a fresh alignment and I was all set. The only thing there wasn't time for was wheel balancing.

This weekend I had to go out of town for some business. My wife took the truck along with our horse trailer and 3 horses out of town to a show. On her return trip she called me to say the front end started making a horrible noise and shaking pretty bad. I was only an hour behind her on the freeway so I told her to sit tight and let me catch up. When I got to her, this is what I found:



Seems someone left the driver's side hub locked for some reason so the axle was spinning and when the U-joint let go it tore itself to pieces. I unlocked the hub and drove it home about 150 miles no issues. Last night I tore it apart figuring I would need a new outer shaft and a U-joint. If only that were true. Here is what I found:

Outer shaft



Inner shaft:




It actually pushed the upper ball joint out about 3mm:


And took a chunk out of the lower:


And a nice gouge out of the axle tube where the seal sits and tore up the inner seal/bearing:


There are several wins to this story. When it came apart, she was just getting back on the highway from getting fuel and was going less than 40mph. Additionally, while this wouldn't have happened if the hub was unlocked, I am scheduled to race the truck in 2 weeks and it would have happened on the drag strip with a potentially worse outcome. And finally, in looking for a fix, I scored a complete Dana 60 front axle for an amazing price.

Thanks to Nolan (4inchlovin) and Nick (weekendwarriorfsw32) for being willing to drop everything to rescue us. Also to Clay @ Riffraff for phone support and input on a fix. Rep these guys when you see them.

 

Ouch Peter, that really sucks. What brand were the joints?

 

I'll have to go back and check. They had a 3 year warranty but unfortunately, there is nothing left to take in for credit.

 

There are also two people that need imaginary reps that arent on this forum and that is my friend Dwayne who left a BBQ/pool party mid swim to go hook up his dads truck to there huge car trailer so he could tow the excursion home if needed and i would take the horse trailer and to Nick's friend Chris who I believe was also willing to come with Nick and help out. Ofcourse Peter if we had known the extint of the damage we probably woulda opted to tow your rig back instead of pulling the three horse but THANK GOD you all made it back safe.

Also Reps to Peter for the use of his truck and his wife Sharon for towing our horses up to the show.

P.S our "barn truck" 1992 F350 cc lb 460 made it there and back no problems minus the three tanks of gas it used... I had three people ask me if it was going to make it ok and if it was "road worthy". hahaha

 

daaayuuummmmm! glad nobody was hurt....that sucks....being that it gouged the axle housing is it looking like youre gonna need another front axle?

 

Do you think this was the root of the vibration you have been chasing?

Edit: Reped him!

 

hey this might be an alternative for you...found this over on PSN and thought of your truck....the front axle already has powerslots and warn hubs also...

02 Axles - PowerStrokeNation : Ford Powerstroke Diesel Forum

 

I don't think so. The U-joint that came apart was just put in on Thursday and it failed on Sunday. I hadn't driven it but about 4 or 5 miles myself after the fix.

Thanks for the tip Bill. Missouri is a bit far for my needs. I managed to source a D60 out of an 03 F350 locally for pretty cheap. Should be picking it up today.

 

good deal....and yeah that would be a haul....didnt look at the location when i saw it....oooops...

 

Picked up a low mileage Dana 60 with 3.73s today for $300. Totally complete brake rotor to brake rotor. They even included the driveshaft. I don't need it but I have it.

 

Nice!!!

 

Be sure to share the brand name with us.

And I'd take the outer shaft in with you along with the receipt and ask for a refund on the u-joint. Tell them it didn't work out too well and that, while you couldn't find all the pieces from the u-joint scattered along the highway, you'd be happy to leave the outer shaft in their place.

 

I agree that should be more then enough. I would recommend going with spicer joints. Well worth the money and never had one brake on me. I need to do the same on my truck, I noticed that my one cap is busted and I need to head it off before I join you. Check out eBay for the spicer joints, they have some good deals on them, with the stub shaft and everything if needed.

 

Wow, That is some serious carnage there Peter. At least you got a suitable drop in replacement.

 

It happens. On our 4x4 trucks I always grab and turn the front driveshaft to see if everything is doing what it is supposed to do when I am doing and oil change. Its part of my 10001 point check. lol