I have an 89 F250 4x4 with the independent front suspension. Last week I discovered (in a snow storm) that I was not driving all 4 wheels. After removing the drivers side locking hub, it was obvious why. The axle tip was cocked in the hub, and was facing the upper rear of the truck, and the spring clip on the end of the shaft had ground all the splines from the mesh gear, and did a number on the axle splines too. Upon disassembly, I found the differential end of the axle to have sheared splines as well (about 1/2 " from the shaft tip and about 1/2 the splines). So, I got a junkyard axle and hub assembly, inspected the differential spline, which surprisingly seemed to be intact, and went about trying to install these new-old parts.

The problem is the spindle hole is not directly aligned with the differential hole. In order to get the axle into the diff, I need to pry the axle knuckle and work the axle through the spindle. When it's finally seated, the relaxed position of the axle is toward the lower front of the truck. The tip of the axle however points toward the upper rear of the truck since the dust plate leverages off the back of the spindle mount bolts.

I figure I must have a bent control arm (the expensive differential cover really), but I did also discover that the lower ball joint is worn.

Is it possible that worn ball joints could cause the spindle to be positioned so far out that it would cause the axle to become cocked in the spindle as I've described??

I will elaborate more on this if anyone cares to discuss this with me.

Thanks for any help,
Greg

 

Well, in case anyone cares, I found my problem tonight (of course, during tonight's snowstorm)

I had reassembled my wheel last night, without the axle installed, and all the bearings and holes plugged to keep out water, and figured I could at least still drive the truck in 2WD. Took it for a 2 mile test drive last night, and had no problems. Plowed the driveway tonight right after work, (in 2WD of course) and was just about ready to head out for the night, and just happened to jump out of the truck for something before leaving. I looked at the wheel and was horrified to see it was angled in at the top at about a 30 degree angle. Brought out a light, and what did a find? A completely fractured differential cover/control arm. It broke inboard of the leaf spring from the bottom, and had split both sides. Wow. I guess that answers all my questions! I just can't believe it happened in my driveway. It's a good thing I decided to take it for the test spin last night, and to plow before I left tonight, or else I'd have been looking at a tow and a walk home in a N'or Easter! I guess the axle was holding the thing together.

Hope this helps someone with a similar problem.
Greg

 

Greg ,
Is it possible you hit something in the snow ? Ive seen worn ball joints , but never enough to bind the axle enough to do the damage you described ? I may be wrong ? Usually worn ball joints make steering stiff and clunking noises .Im thinking the ball joints would have to be literally all to hell before it would jam stuff up that bad . Id have a good look inside the hubs to rule anything going wrong in there .Ive seen the springs inside those goofy locknuts that hold the hubs on break and the whole hub assmbly come loose .The truck I saw this on was loose enough to engage one hub , but not loose enough so youd really notice a lot of slop in the steering . Only when I jacked it up to see what was going on did I notice the wheel and hub had a fair amount of play . Wish I could have a look at it . Any questions , post back .
Paul