Okay, I have posted questions about my issue with rear axle. I have just recieved word that the warranty group that was supposed to fix this problem twice already is saying I'm on my own this time (the Third time), the pinion bearing has gone out each time pressing into the carrier. the first two times it cracked the carrier this I caught it in time. Any IDEAS on the possible causes for this issue?? I beleive it is related to either the tranmission or the tranfer case. HELP ME!!!

 

I would look for a new axle. I can't see the trans or the case causing your problems. Soemthing must be out of tolerance in the case?

 

What year rig, axle type . what size tires are you running. just need a bit more info. but like rtm said i doubt the tranny or tcase i causing your issues.

 

Oops, sorry 96 with 103k on the clock and 5.8 with e40d and 8.8 with 3.55 trac lock running 33x12.50x15 on 15x10 rims. with the ford add in blocks between the axle and leaf springs. this seems to happen about every 3000 miles or so each time and this bronco only gets driven to and from work hasn't had any towing since the first axle incident hasn't been off road except for dirt roads since the second axle this third axle has only seen paved ground due to my current job and not having time to get to any sanctioned off road areas since the new texas off road laws have been passed.

 

hey how about this, after reading several posts and seeing that someone has the stop ang go clunk like I do from the post "Body movement on sharp turns and quick takeoffs&stops" Does anyone think that may be the drive shaft slap that was talked about could be a culprit to my axle issues since I have the, according to description, exact same axle knock or clunk in stop or go and turning situations but more along the stop and go line? I know my bronco has seen better days and I currently baby it to death (wash it, so it shines brighter than a new concept bronco, oil changes every two months or 2000 miles which ever comes first, only premium gas, and ......well you get the point). Seems there is most likely more of a drive line issue than I thought but like I told the extended warranty group they said they would fix it the first time and that is what I expect. Any way any ideas would be gretly appreciated since the warranty group is not telling me anything. Also another problem tha just recently came up not sure what it is or how it relates to the axle issue, the e40d transmission has a problem to where when starting up if I leave over drive on and run down the road depending on how hot it is out, it start to shift really hard was at normal temps. if I turn over drive off after first starting up then cruise no problem but of coarse burns a lot more fuel. Could this also be some how tied in to this problem? if not no problem I'll rebuild it myself if needed.

 

your rear end has a speedo sensor in it. if its not working properly then it will cause issues with the tranny. I would find another rear axle from a wrecking yard then find a different shop to rebuild the whole thing axles, bearings, seals and ring/pinion if it needs it. then just swap your current rear out for this other one, take your driveline in for balancing and be on your way. this will cover pretty much everything. i think who ever did your rear end work originally didnt install them correctly.
good luck

 

Thank you, for that. I also spoke to a very reputable ford dealer and spoke with several of their technicians. they said something very similar since the vehicle is used on road only. They said normally you would see something like this happening repeatedly with a vehicle being used off road and going from hard surface to soft repeatedly, putting stress on it at different angles and with the varying speed differences between surfaces. something to that effect. Again thanks, think I will do so but in doing so I think I'm just going to track down 3/4 ton axles fro front and rear. and go that route. As, well as get the rest of the drive line checked out and make sure is all lined up correctly.

 

ok, for a rear axle then you will need to find a sterling 10.25 because of the speedo sensor in the axle. also i believe you can just swap out the front spindles out to get the 8 lug pattern up front. do a search on here.

late

 

Great will do, Thanks for narrowing down that search for me this should really help scoot me along.

 

I read back over your other posts. If this was "fixed" under warranty, then I do not think it was fixed at all. I may need some more info. though. From what I gather, the pinion is moving back and splitting/cracking the carrier. If it was just a lose pinion nut you would have had some vibration, a clunk when you put it in drive/reverse. Which I think you mentioned, this would be installer error. They did not set the preload correctly or torque the pinion nut properly. The inner pinion bearing is pressed on the pinion. The outer is not, but it would be really hard for that bearing to end up in the carrier. Did they replace just the carrier or the whole rear-end, drum to drum? Even if it is something else causing the issue, they should have caught that on the second time. This sounds like a poor installation to me. Is this the dealer you are dealing with? Most reputable Ford dealers offer a warranty on any work they do. If the warranty company dose not want to pay the dealer should. A rear end takes some experience to set up properly, it is not just something that can be slapped together. Maybe try asking the Transmission, Differential, Axle and Transfer Case forum on this site. Good luck.

 

WOW, you're right on target. Yes, the carrier was cracked the first two times. this time Fortunately I caught it before it could do to much damage. As for who istalled it yes the first was installed by one dealer and the second was installed by another dealer due to me having moved. Both of which are not the reputable dealer I mentioned before. But, my dispute is with the warranty group just based on them statting a 12 month 12,000 mile part warranty expired 5 months after installation because the vehicle warranty expired at that time. Which even after speaking with legal council states that is not so unless is in writing. When the warranty group was asked to give in writing they said they couldn't/didn't have it in writing. They said is industry policy, (of course my aguement is if is policy then should be in writing), but round and round I gone with them. They are finally to the point where they say if I get the vehicle towed to a particular shop which is in georgetown TX then the part supplier will pay for the repair work. Down side is that is 45 minutes away. And the way I see it if it was supposed to be "FIXED" in the first place and there policy is so set in stone why would they give in now? I haven't even mentioned anything legal YET, but if this takes much more I will bring legal into this just so they repair/replace whatever the cause is and the broken component at no charge to me what so ever. IN WRITING there policy states "will provide cusotmer with cause of malfunction and repair/replace broken/malfunctioning component(s)" This I quoted to them and they still try to tell me that the vehicle warranty is expired, whaich as a consumer is besides the point if wasn't ever "FIXED" in the first place.

 

Sorry, About being so long winded. just upset about the whole thing since I baby this bronco like no other vehicle I've ever owned and this is for the most part the only real issue I've had with it other then expense otherwise.

 

Okay well, today I went an wrote to FORD online and told them the situation just to see what they might have to say. Never hurts to check with the manufacturer. And, besides they have typically been pretty good about giving me godd ideas or information about the various things I have writen to them about.

https://www.customersaskford.com/Kan...aunchsite=ford

Here is the link in case anyone ever wants to ask them a question or two.

 

yep, if I am reading right the 12 month 12,000mi warranty was for the work done, correct and not the vehicle warranty originally purchased with the vehicle. Is the Warranty group with Ford or a separate company? I can tell you they did not fix it right the first time and I would not settle for anything less that a completely different 8.8 rear end using Ford parts. I would also try to see if this was an issue with the previous owner. The 8.8 is a very tough rear and if built properly should last a very long time.

 

It is a seperate company, which I will not mention for now. but the first two times yes they replced the entire axle assembly this time now they have caved to say they will pay for the repair "in good faith" B*#@SH#@. Good faith my rear yes the part warranty is seperate because they have not provided me in writing the part warranty expire dwhen the vehicle warranty did. Any way they are will to have it reapaired but say I have to pay for towing and now they will have the shop find the cause. but anything else I have to pay for is what they are telling me. I'm going to call them in a few minutes and tell them this is my final call before bringing another party into this. I will not mention who to them, they can figure it out or give me what I rightly deserve. Due to them never having fully diagnosed the cause, if it turns out to be something that wasn't covered by the warranty fine I'll deal with it. But, if it is something else in the drive line then I already told them they WILL pay for it. Regardless of vehicle warranty run out or not. Part warranty still stands till they provide evidence otherwise. But, thanks for the input I was honestly begining to think no one was understanding the issue at hand or my explenation of the problem.

Thank you to all who gave input!