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OK so I have had this issues for a while. When I am in the sand (or anywhere offroad) 03 F150 5.4l into either 4hi or 4lo, as soon as I get on the throttle the driver's side CV axle comes apart and the axle tube of the front differential cracks open. The CV axle was replaced with a new one from ORielys back in 2015. Since then I have used the lifetime warranty on the CV axle no less than 25 times.
Today we replaced the front differential thinking that was the cause of all this. After getting it all put together I took it out to test it and the same thing happened again!
Now I am thinking the CV axle I purchased may be the problem, but I am not too sure. What are your thoughts?
Doing some more research on this. The brand i purchased from O'Reillys was actually Precision. According to the specs on this model the compressed length is 19 and 11/16 inches. The Duralast model from Autozone measures 20 and 1/4 inches. That is more than half an inch in difference. Would this impact anything?
The truck has a 6 inch Fabtech lift on it. No leveling kit or torsion keys. I have been able to do some pretty aggressive wheeling with it in the past.
Thinking back this never happened before I purchased the Precision brand CV axle many years ago. I am thinking of getting a different brand and seeing what that does.