This may not be a case of the axle tube crushing due to the weight of the truck/payload, at least directly. The impression I'm getting from this document is that the welds are tearing under torsional load. My guess is that the welds start to fail, and the axle wraps under load. When the load is removed/reduced, the spring seat slams back down into the axle and causes the deformation. Again that's a guess, and I'm not an expert. I have one of the affected trucks, and so far my axle looks fine, but I still want a new axle. To see that Ford has gone back to housings with consistent thickness is telling. As for the MIG welder settings, Ford appears to be setting the machine up for spray transfer, probably for deep penetration in one pass.
That weld in the video looks like crap, lol welding it solid doesn’t allow for any give and I’m betting it will crack more next time as a result. My guess is the tubing is too thin.
It seems like forever; but I Finally received my recall notice. My truck is getting the full axel replacement. Thank you for these videos. Very informative and accurate! I DEFINITELY didn’t want the weld. I bought my Truck in Ontario at Ridgehill Ford. We are now on Vancouver Island. I don’t know anyone at the dealership and was prepared to fight in order to get the replacement NOT the weld! I’m glad to say I didn’t have to plead my case! After inspection they informed me that my axel has in fact failed and will be replaced with a new Axel this Thursday. Thanks again for posting this and a big Thank you to Westview Ford for their Service! This is not a work truck. I use it to pull my fifth wheel.
Let me just say, I am a professional welder and if one of my guys put a stack of buffed out boogers down like that he would be promptly demoted to mop boy and hope he doesn’t mess that up.
@@markremillard9237 And do they actually think welding that already thin axle tube is actually going to fix the problem? The tube is still going to bend regardless under extreme weight.
@@markremillard9237 I absolutely agree, when you’re paying that much money for a damn pick up truck and they offer you a Band-Aid. They should replace the entire axle with no questions asked.
As a welder, I can give you my simple explanation/understanding. As forward/reward torque from regular driving is put onto the leaf spring bracket, the welds on either side (at the starts/beginning/ends of welds) will be taking a lot of the forces. As the forces are applied, the welds will start to fatigue and allow slight lift/rotation of the bracket, as this fatigue increases it will put force on the tube. The tube is very strong when forces are applied/dispersed around the circumference however, as the forces are applied to smaller areas i.e. the front and rear of the bracket, the structural integrity of the tube becomes compromised as per the intended application. The reasoning for the feeler gage is due to calculations pertaining to the structural integrity of the tube i.e. if the the bracket has lifted/rotated over a designated amount, the calculations say the tube structural integrity is compromised. If the lift/rotation is less than the designated amount, the tube is sound, and the preventive (stop the lift/rotation) measure (weld) can be taken. Wrapping the bracket with weld in the beginning should absolutely have been done in my professional opinion. I feel for the owners who are stuck in the "wait for new axles." -Cody
It's common to only weld the sides on spring perches. The perch contact area on the tube holds the weight and the weld keeps the perch from twisting on the tube. Welding on axle tubes always warps the tube as the weld shrinks when it cools. Since it's a full floating axle, Ford probably thought the warping wasn't a big enough concern but the proper way to weld an axle housing is to have a fixture to keep it straight when welding. It's seems to me that the extra welding is just a bandaid.
100% agree! We all know Ford doesn’t hire professional welders. What you’re getting at Ford is a mechanic that has next to no experience in “real welding”. I’m a journeyman certified Welder by the way. ✌️ I’ll be the first to say that the weld in the illustration made me cringe. 😂
I am amazed that they are using .052 hard wire. 25-30 volts would be about 250 - 275 - 300 IPM and I'm suppose to believe every Ford dealer has a Miller 350 machine (or equivalent)? I have to agree that .035 would be sufficient Personally? I'd use .045 dual shield (I certified .045 dual shield 4G and 6G up to 1" plate) but? regardless of how much weld metal you put into the weld/repair.....it doesn't change the fact that Ford used too thin of a wall thickness for the tubes and has engineers that design by the almighty dollar, not by strength and structure. Seems that's the way of the world anymore.....design to the very minimum you can get away with.
@@GeorgiaHyway fast and hot seems to be what they’re doing … and in the process looking like shit. I’ve checked my truck too and it’s perfectly fine. No weld getting put on mine. It’s got to have some flex or guess what? It’ll crack again in the same area. Fords engineering people should know better than this and it makes them look like a bunch of a amateurs by suggesting the fix be this. Ridiculous is what it is. The stronger tubing is the only answer on a Super Duty Truck. Who they trying to fool? 😡
1. The recall applies to very low percentage of vehicles (aprox. 35k of ~1.2 million). 2. The weld is "boxing" the tube. It's common practice in civil engineering but not common in the automotive world. It'll prevent the tube from collapsing. 3. Weld procedures need to be specific. A "weld" is not JUST a "weld".
Having spent 45 plus years welding for the trucking industry I can tell you that welding the pad all the way around is a bad idea , eventually the pad will take a chunk out of the axle tube and you end up replacing the tube down the road after the recall is over .
Not gonna be Fords problem by then...they ''fixed'' it. That's the problem. They started out penny pinching, and now they have problems, so they penny pinch their way out of it.
The problem is the contact point of the spring seat to the axle is too small . I would suggest removing the spring seat and replacing it with a larger mounting surface to the axle .Spring shops deal with this all the time . It's a great time to be a welder .
Any larger contact point of the "spring seat" or base would enlargen it and interfere/hit/impede into the u bolts that are secured to the set width top plate wouldnt it or do spring shops change the whole thing ?
@@brianblithe2271 go to @6:22 the crushed area is what needs to be reinforced. on the left you can see how much you can reinforce between the u bolts . you can see on the right the spring seat is concentrating the load on the axle not distributing it .i would find a better spring seat .
The reason for checking the gap is to ensure the seat is taking the weight not just the weld area. The weld is likely more to add additional surface area but the real weight is taken by the entire seat not just the weld.
Looks like the torque of the motor under load is causing the axle housing to twist, ie the reaction of the pinion gear driving against the crown wheel. The 4 U bolts obviously cannot resist this torque putting all the force onto the Leaf Spring Bracket. Provided the gap is 0.002 or less welding should fix the problem. All replacement diffs should have this bracket fully welded, otherwise it'll happen again !!
When you drop off the truck ask the service writer for a copy of the combo mechanic / welder's cert's and an X-ray of the finished weld from a certified X-Ray company. Tell him your insurance company asked for it
If ford actually claims work will be done by certified welders then asking for proof of that is fine. Asking for an X-ray will just get you laughed out of the building, Its a spring seat, not a nuclear reactor. That being said ive seen some of these "certified welders" fresh out of school and their welds are horrible. I dont claim to be an professional welder myself but as a mechanic/hobby welder i can lay down much more effective not to mention nicer looking welds then many of these "certified" folks. Its all about practice, the piece of paper just proves you were taught some theory and safety practices.
I'm not an engineer but I fail to see how that weld increases the structural integrity or load bearing capacity of the weak axle tube. I feel I now have a very expensive truck with a design flaw and a bandaid fix proposed by Ford corporate. I'm pulling a fifth wheel and even though I'm well within the load capacity (or so I thought) I now have a situation where the abuse imposed on the truck by roads, or other conditions leaves me vulnerable to a serious situation. I could've used an F250 but opted to add some safety margin by going with an F350. Did they weld/repair all the new trucks that had this flaw? No, they replaced the axles. I see a class action suit on the horizon.
I don't see how on earth welding the fore/aft end of the perch could possibly prevent the crushing failure.(?) If Ford isn't going to replace the axle it should at least engineer a proper fix, which I would think would be completely disassembling the axle and either sleeving the entire tube, or sleeving at least the top half of the tube. Also, as others have noted, I doubt the weld in the photo would pass an automotive weld inspector.
Thanks for the great video . I have a f250 tremor gasser, built inside this recall window , funny part is ,I am in the process of having a new Torque converter installed tuck only has 5000kms on it . Starting to feel ripped off by Ford .
Great Video! I completely agree with you and your analysis...specifically the two points you made. 1. Ford (actually) Dana should replace all the axle housing (axle tubes) on ALL Dana M275 rear axle housings. 2. @13:30 - you are correct.....that is not a good weld...poor weld surface attachment between the spring seat and the axle housing. So......looks like I will need to address some things on the 2022 F350 7.3L Tremor I have coming soon. 1. The 10R140 transmission......contact Next Gen in San Diego for some upgrade parts...torque converter, clutches, etc. 2. Get the thicker walled axle tubes for the Dana M 275 rear axle. Next Gen has a very good article on the GM 10L1000.....with all the weak internal components and parts...same weak components and parts are on the Ford 10R140. Next Gen has high quality aftermarket components and parts to get both the GM 10L1000 and Ford 10R140 equipped for heavy duty work.....and greatly improve reliability, durability and longevity for both the GM and Ford trucks.
I think the fix is a strategy to negate the twisting of the axle to minimize the probability that the axle with separate from the drive shaft. It also gives the lawyers a leg up on defensive motions in the future if needed. I'm not sure where this is going but we should all raise hell till they address it satisfactorily.
Ford's screw the weld repair is like pissing in the wind. The spring perch doesn't even require being welded, as the perch is sandwiched by the tube and leaf spring. The perch holds pinion angle until tightened up. IMO, they should be fabricating a doubler shaped to the axle outer diameter and a new spring perch to fit that should be be able to rest on the new doubler. With building up the thickness, the tube won't be susceptible to crushing. None of this inspection is checking the straightness of the axle tube. A laser light shined straight through the housing should be perfectly aligned. Just like bore alignment of a rifle scope installation. This however will require the axle shaft removal.
Dear Gunga Dinn: The perch has to be welded lest the entire axle would twist inside the clamping devices. Think, think: big high torque diesel engine, torque multiplied with the trans in low gear, then that torque again multiplied by the rear axle ratiio (possibly a 4 to 1 ratio). Not welded, really. I've adapted several different axles into different vehicles into which the axle didn't belong and always welded the spring perch, it's a requirement.
Disappointed I'm just seeing this now. Just picked up my 2021 6.7L F350 Super Duty Tremor on Saturday. The dealership told me there was a recall that needed done on the axle before I could pick it up. They said it was something about checking a weld. Made the purchase this past Thursday. The dealership then told me the recall was rescinded on Friday but couldn't provide any paper like in the links above, so they printed out the Oasis system report on my VIN and it doesn't show any recalls. To top that off, the front passenger wheel started squealing like crazy yesterday morning so now I'm off to the repair shop in a couple of hours. I'm feeling like I got taken.
Ford has lost my trust because of this, and also many other faulty design issues I've seen. When I buy my next truck, it will not be a Ford, unless they do a complete 180 on their strength and quality.
My guess is it’s a torque related issue on the tubing. That would explain why the F250’s are not needing a repair or new axel. Nothing to do with weight on axel.
Honestly, who in heck ever heard of an axle collapsing on a brand new F-350 (built Ford tough) Super Duty? With a diesel this is at least a $65,000 truck, this is an unconscionable engineering failure on the part of Ford! Then to come up with this Micky Mouse fix (sorry Micky), is insulting to anyone one who knows anything about drivetrains. That welding job is a joke, you'll probably get bearing arc unless you take the differential completely apart and run the risk of warping the already compromised axle tube. That spring seat is there primarily to position the pinion angle so the u-joints don't fight each other and to steady the load from above. This is what happens when truck companies are run by accounts and milk every cent out of their suppliers by opting for substandard components and spending that money on advertising. Like Ron said, "you can't fix stupid"!!
@@johnbell238 No doubt, but it's Ford's responsibility through quality control and monitoring it's supply chain to make sure they don't T-bone their customers with substandard components or "substitutions" with parts that amazingly have the same assembly code. This often happens at the behest of accounting department interventions circumventing and compromising engineering/operations which all of the US builders have been guilty of.
Remove the stock seat from the top of the axle......get a piece of channel the full length of the axle tube clamp it in at the ends put new longer U bolts.... no welding required... and a lot cheaper than a new axle
Kinda had the same thought as well when I herd about this issue and the shitty fix they came up with. Although I think they would probably still need to weld it to the axle it would still be a better fix than what they are suggesting.
They are using the weld to distribute the load over a bigger area. It l may help a little, but to me this is just buying time. If the truck is used @ near its maximum load, the welding will not help. To crush like that means the tube is way under strength. Adding a few % to the load area is not going to solve the underlying problem.
I don’t think the purpose of the weld it to prevent the crushing, I think it’s to reduce the odds on driveshaft separation and crashes as a result. Pretty much a band aid to reduce lawsuits for death or injury.
You would think Ford would have plenty of axles laying around the factory since they can not build new trucks because of the “chip” shortage. It’s getting to be embarrassing to own a Ford truck lately
Looks to me like the axle tube thickness is sub par. There should never be a tube crush like that. Been a Ford man all my life till just recently. You couldn’t give me one now. Such a shame. The company is killing itself slowly.
You know,i agree.Im also a Ford guy(im 66),and just disappointed in everything coming out of Ford lately.I did bite the bullet and got a 2020 Fusion after my retirement,and like it so far,and ill never sell my 95OBS 7.3PSD.I want it buried with me.But being a fan of the BlueOval isn't what it used to be.smh.
ALL manufacturers.....Ford, Chevrolet, GMC, Dodge (Ram / Sheep), Nissan and even Toyota have quality issues and problems. People should take some time and read on the Chevrolet / GMC and Dodge truck forums. GM is having countless quality issues and Dodge is just as bad, maybe worse. It is a VERY competitive market and EACH manufacturer faces producing a competitive product at a cost that yields a profit weighed against cost of expected / potential warranty claims. EVERY manufacturer uses cheap inexpensive components and parts often designed to last just beyond the standard warranty period. Regarding Dodge trucks. It is absolutely shameful that executives implemented the brand name change back in 2009 - 2010. On a few fronts, it was an idiotic and stupid decision. It would be like Ford changing the name of their trucks to Edsel. They should have kept the Dodge name. They messed with the heritage and legacy of the Dodge name..."The Dodge Boys" - brothers John and Horace. In addition, they messed up the heritage and legacy of the DODGE Power Wagon. Besides, the Ram brand name was a poor choice even if it had been used previously as a "model name" for the Dodge trucks. The Ram name makes me think of Sheep.....not a good name for a truck.
You would think Ford would use a better looking weld for an example. I'm not a pro welder, but my welds look better than that. If this only affects 20 & 21 F350's what makes the 2019 and back models OK? What did they change ? Thinner tubes to save a buck would be my guess.
The welding fix seems to be a feel good stop gap fix. We don’t have parts for the proper fix so we’ll make the owner feel good that we did something. May be the weld will help slow the damage (till it’s out of warranty)…. Seems to me a larger surface area for the leaf spring seat bracket would hold better. Such as the pad wrapping further around the shaft. Also notice how much wider the bottom support bracket for the u-bolts are.
Since there is no parts available, is Ford gonna pay all the people that use these as work truck for lost wages and time and revenue? Huge oversight making an axle tube so thin it crushes. I've see Toyota trucks form the 90's yes the small ones carry way more than they should all the time and no axle crush.
Everyone take note. Ford doesn’t make these axles. The f-250 with out heavy tow package has the standard sterling 10.5 they have had since 99. The f-350s single rear wheels with the diesel come with the DANA M275. I know this because I own one. They are made by Dana. HOWEVER it doesn’t excuse fords BS response. Personally I have always driven fords, but my parents had a f-150 with a 10 speed that was never right. I had a 2019 f-350 which suffered through multiple warranty claims. My trust in ford is lost. This is not your dads old 7.3 powerstroke. These are manufactured for the lowest possible cost.
Made by Dana to Fords specs, it looks like a combo of CFCS (Cheap Frigin' Chinese Steel) and the wall thickness is to thin, (GVT mandated millage requirements.)
Great Comment! Your last statement says volumes regarding cost, competition and most important...quality of components and parts. However...and just an FYI...the 10.5 axle is NOT a "Sterling axle". There is NOT a "third party company" named Sterling manufacturing axles for Ford. Instead, it is a corporate axle...made by Ford Motor Company...at the Ford axle plant located in Sterling Heights Michigan. The 10.5 axle has mistakenly taken on the "Sterling name" most likely because Ford executives, management and employees refer to the plant as the "Sterling axle plant"...BUT, that does not make it a "Sterling axle". It appears that numerous internet posters incorrectly used the Sterling name years ago...and unfortunately the incorrect name stuck.
I am a retired hdr mechanic welder local 12 operating engineers union ... And i agree whith you on the reason of welding displacing the load . But it is a bullshit idea if the tube is too thin nothing will fix it but replacement of the inferior tube . I find it ironic that ford has such a collosal fuck up , whith no parts to replace it whith . Especially after ford pissed off navister whith their own diesel engines violating the contract whith international causing us to nolonger get parts for international engines . I hope ford takes it in the ass as hard as we do for owning their trucks whith now obsolete engines
That's an ugly weld. The reason for changing grounding positions is to keep it from arcing through the bearings. You want to keep the ground close to the weld area as possible. Have seen the results of arcing through the bearings. Have to replace all the bearing. In a diff. It will also ac between the ring and pinion too.
So…. Why is it only F350 SRW Diesels…. Why not F250 with diesels and tremors with diesels…. I know we are all speculating they are next on the recall but come on Ford! New axles for us all who need it is soon to come once the law suits start.
@@tcr2237 I’m not entirely sure because it likely auto includes may other packages from the factory. I know on the gas models they only come with 4:30 gear ratio
Sure weld all around the perch and guaranteed the whole thing blows out instead of crushing and cracking Guaranteed! Oh sorry we don’t have parts to fix our f up so your SOL ! Thanks Ford !
That weld is garbage and I don’t see how it actually fixes the REAL problem. I have a 04 (that’s paid for yaay) and I’ve never had any issues with the Sterling 10.5. I know the newer trucks have way more power and tow a heck more weight, but I tow a 20k 5er, 2-5 thousand miles a year, tuned so she puts out decent torque numbers. Not sure why Ford stopped using the Sterling units. I’ve heard nightmare stories of open Dana units sitting at Mexican seaports rotting from the salty ocean air, waiting to be shipped to the US. Dodge had a bunch of bearing issues in the early 2000’s because of that scenario. QC is obviously an issue @ Dana.
I had an obs f250 with the 10.25 I believe. Tough truck but also like you say it didn't make barely half the power even with a tuner than the new diesels. I have a dana 80 in my f450 dump truck and dodge 3500 and pushed the f450 to the limit. It makes even less power with the 7.3 IDI but 6 tons in a 9600lb truck is a lot when it has a GVWR of 14.5k. Axle rating in that truck is 11k or 12k thought.
You are fucking crazy that this is the fix.....they are welding perches where they never have been welded to make a band-aid!....these aren't failing because of weight its because of the torque of the housing trying to spin...thats why they have them check with a feeler guage to see if it started to happen yet....BTW if I got my truck back with a weld that looked like that I would leave it there.....are they expecting a normal tech to have the knowledge of how to do the weld correctly?. Just because it's welded doesn't mean it's right......this whole thing is ugly on ford's part
I would not trust a Ford dealer (or any non commercial OEM truck dealer really) to weld a mud flap bracket back on let alone weld on an axle housing. Plus the weld only fix seems incredibly half ass with no gussets or plating. I guess the plan should be inspect your axle yourself and if it fails load up to max payload and start doing full torque throttle rolls ons and brake-torques all the time until axle is crushed lol.
So it would seem there has been a miracle! After the dealership told me my Axel has failed and my truck is unsafe to drive; now only 2 days later, my trucks Axel is now a pass and safe to drive! They will be conducting the weld, even though I am pushing back and requesting the Axel as promised! I am speaking to Ford directly…nobody cares! So NOT impressed with Ford. I wish we could all get together and force them to do the right thing!
Why? The axles are no longer being made this way, and it wasn’t a Ford problem in the first place. Dana changed their procedures without notifying Ford, check out the other video. I imagine this recall is costing Dana a pretty penny.
You did not mention engine choice for the 2022 F250 SD truck...6.7L diesel or the 7.3L gas??? Virtually every manufacturer is having issues, problems and recalls.....on a variety of things regarding weak parts, and china made electrical and computer components and modules. Next Gen in San Diego California has high quality aftermarket parts (torque converter, CNC machined aluminum billet pistons, stronger CNC machined aluminum billet Stators, additional STEEL clutches, etc.) for the 10R140 transmission...to "bullet proof" the transmission. Some F250 (NON Tremor) SD trucks come with the Ford 10.5 rear axle. If you get the Tremor Package, both the F250 (Class 2 ) and F350 (Class 3) will have the Dana M275 rear axle.....which is the axle with the problems in this video. The permanent fix is to replace the LH and RH axle tubes (axle housing) with the new part number that has thicker wall tubes. The new multi speed transmissions are very complex. I would bet a fair amount of money there are NO aftermarket upgrades for any of the Toyota (Class 1 - 1/2 ton trucks) automatic transmissions...and doubtful about any for the newest Dodge (Ram) trucks...however, probably forthcoming. There are plenty of aftermarket upgrades for the older automatic transmissions for all of the Big 3...Ford, Dodge and GM. Maybe I am wrong, but the fact that you even mention the Toyota truck.....tells me that you do not even have a need for a Ford Super Duty....or a GM Heavy Duty or Dodge Heavy Duty truck.
The weld in the picture is laughable. I can't believe they used that as an example photo for a major auto manufacturer instruction example. Makes you wonder who at Ford has any common sense. If the tubes are that thin to start with this is not going to help enough anyway.
First off, that's a bad looking weld, second, you should never DC arc weld on something that has internal ball or roller bearings because of what is called bearing arc. I arced a ball bearing and it wasn't a pretty sight nor was it cheap to fix. The differential should be completely disassembled and cleaned inside and out before welding.
@@roadglide1142 I believe the torque that the diesel puts on the rear end is the problem. As the engine applies torque to the rear end it wants to rotate the front of the rear end down towards the ground. It’s the twisting force that sets the tubes demise in motion not the crushing force from the payload. Who knows maybe gassers will be next in line.
The weld in the Ford Instruction Bulletin is sub-standard and would not pass a weld test buy an AWS inspector. My personal opinion is that the load on the axil has little to do with the crushed condition of the axil at the spring seat. I would say the compressive force of the U-bolts tightened to the spec of 195 ft/lb is far greater compressive force on that area of the axil than the weight of the truck and load on the truck. The reason I'm saying this is that folks are chiming in on various on line conversations indicating their axil looks compressed and has paint chipping off the axil at this location on brand new trucks that have not even had a load on the truck yet. It's also being noticed by both 6.7 and 7.3 owners. My 7.3 F350 Tremor has signs of crushing and it's 3 months old and never carried a load to date.
Odd that your 7.3 shows signs. My 6.7 that's pulled a 5th wheel with 3K lbs pin weight and 15K lbs towed 11K miles in the last 7 months seems to be fine (visual inspection). However, under heavy acceleration I do feel driveline shudder. Has me a bit worried.
@@skremese Exactly and that's my point. The axle deformation is originating at the factory during install. The reduced tube wall thickness combined with the torque on the U-bolts is deforming the axil, and that's why folks are finding their new truck off the lot with paint chipped off the axil between the u-bolts. The axle twisting under heavy acceleration and load with the 6.7 is tearing the welds loose over time and causing the secondary symptoms you are experiencing. There is actually two problems that are occurring in succession and both the 7.3's and 6.7's are susceptible. The first happens at assembly and the second occurs in daily usage.
@@chrisneuhaus7188 Do you think that their weld "hotfix" is acceptable? I know that everyone is saying how crappy it is but I guess it makes sense than a sub-par/small weld on both sides wouldn't be nearly as strong as a 360 degree weld. If the thing that breaks first is the weld, perhaps fixing the weld would help? On the other hand, they are fixing the issue on new ones by going to a thicker axle, so obviously they do think that that's the better solution.
A lot of recalls on these superduty 1 tons cant imagine a used one having dogshit value for a trade in a few years from now . Im keeping 2004 gmc 2500hd till it dies a mega death
Just add some weld, help get it out of the 36 month ,36,000 mile warranty then it is not their problem. Ford saved a little weight and money making the axles tubes thiner.
I wouldn’t stand for that. Trade it off……I would guess that there will be a ton of F350 single rear wheel trucks on dealers lots for sale on the used market.
Ford sucks so completely…I bought my new 2020 F350, and my first I might add, specifically to carry a new Lance camper after much research on payload capacity and capability. Then I get a recall notice that they overstated the payload capacity and the fix is a new f$k/@n payload sticker! WTF! And now this friggen recall!! And their fix is to remove my entire rear end, do some hack weld job and attempt to put it all back together again?! I paid very large sum of money on what they advertised and it turned out to be a complete sham not to mention what I paid for in the new camper this truck was advertised to carry! What a sorry and dishonest company you are Ford Motor Company, I will be joining that class action!
This is what happens when you buy new. Which is why I prefer buying a few years older. This kind of thing will happen with any brand that chunks out something new.
@@mmardell9262 I hear that and thought I might be avoiding that with a late year build 2020 just before 2021 but that didn’t make a difference unfortunately. Its actually a shame that we can’t trust what they are putting out into the market as new. And yes, all of the brands have recalls for sure, not just picking on Ford here but unfortunately these last few recalls (new transmission recall in there as well) from Ford are pretty damn serious and far beyond what should be piling up at this stage…somebody has taken their eye off ball at Ford no doubt as they are busy trying to rush a ton of new vehicles to market (can only imagine what recalls those vehicles get hit with!). E
@@RT-fy7gt in all honesty most if not all companies don't care about us. They only care about our money. If they do happen to acknowledge our existence, it's usually because we are a potential buyer, and/or and existing one with potential lawsuits.
So they’re sending known unsafe parts back onto the road because they had some hack at a dealer use a welder on it having had no formal welding training? Sounds like a perfect FORD fix! Lol what a joke.
Not true im a ford guy I own a f150 but my mom and my friend both own chev . One is a suv one is a truck . Both needed engine jobs after warrenty ( no warrenty left ) both burning oil and having troubles which chev is famous for . Chev replaced both engines free because they got regular oil changes . Is chev junk.. the answer is yes .. does chev recognize this .. yes they do and they go above and beyond to fix it so I have to disagree with this comment. I'm very disappointed with ford on these new 2021 f150s . That axel tubing is wayy too thin regardless and rusting like crazy very fast . These axels are not going to hold up for years to come with salt roads etc no matter what you weld or do it simply is a design flaw with garbage steel . The only true way to fix this is new designed rear axels with thicker better quality steel but ford can't do that because of the loss they have taken on the trucks that can't he sold sitting on lots waiting for parts . These trucks that are sitting there are having major issues the axel is the least of its worrys . Engine seals on the engines are not being lubed properly from sitting there rodents are going up inside and chewing wires . These trucks are on a lot packed in like sardines and are basically getting destroyed by sitting there a new engine needs oil lubrication to keep all seals in working order. Ford is losing there shirts on this because people are starting to figure this out via social media and RUclips. Ford and other companies are actually in a mess because of this right now but ford being the worst because being a new generation 2021 it also has other issues rusty soft thin rear axels and whatever else. What a mess .. trying to fix this issue with weld is a disgrace and an embarrassment for any ford owner or fan . DO NOT SETTLE FOR A WELD. this is wrong in so many ways you can not sell a new truck and then grind and weld the rear axel and send it back on the road. Yes ford is in a crisis with these f150s in many ways but that will only cause more chaos in the end . New designed rear axel is the ONLY proper fix . Be careful if your buying a new 2021 and up f150 check the build dates if it was a truck sitting on the lot waiting for parts DO NOT BUY IT ford is trying to keep this quiet but biggggg problems with these trucks that sat in the lot a new truck is not suposed to be built not fully assembled abs sit in a lot for months with no emgine start up or being moved this is not how it goes tgis is only because they had no choice . Who's going to suffer from this?? Anyone who buys one of those trucks that had to wait for parts . The consumer not ford from what I can see from this video ford will do a half assed fix and as long as it works itl be your problem .
This may not be a case of the axle tube crushing due to the weight of the truck/payload, at least directly. The impression I'm getting from this document is that the welds are tearing under torsional load. My guess is that the welds start to fail, and the axle wraps under load. When the load is removed/reduced, the spring seat slams back down into the axle and causes the deformation. Again that's a guess, and I'm not an expert.
I have one of the affected trucks, and so far my axle looks fine, but I still want a new axle. To see that Ford has gone back to housings with consistent thickness is telling.
As for the MIG welder settings, Ford appears to be setting the machine up for spray transfer, probably for deep penetration in one pass.
Could be, but I didn't see any evidence of the weld breaking. If the welds are tearing then you could be right.
I think your spot on with the torque under load scenario as the cause.
That weld in the video looks like crap, lol welding it solid doesn’t allow for any give and I’m betting it will crack more next time as a result.
My guess is the tubing is too thin.
"Ford" is not the manufacturer of the axles so mig welder settings would be up to Dana, Dana has sent factories overseas and metal quality has slipped
@@bradsmith5838 torsion strength of tubing would be what we are looking for on these 1050 torque beasts.
Mine 2021 is making a lot of noise
It seems like forever; but I Finally received my recall notice. My truck is getting the full axel replacement. Thank you for these videos. Very informative and accurate! I DEFINITELY didn’t want the weld. I bought my Truck in Ontario at Ridgehill Ford. We are now on Vancouver Island. I don’t know anyone at the dealership and was prepared to fight in order to get the replacement NOT the weld! I’m glad to say I didn’t have to plead my case! After inspection they informed me that my axel has in fact failed and will be replaced with a new Axel this Thursday. Thanks again for posting this and a big Thank you to Westview Ford for their Service! This is not a work truck. I use it to pull my fifth wheel.
Glad it was helpful.
Let me just say, I am a professional welder and if one of my guys put a stack of buffed out boogers down like that he would be promptly demoted to mop boy and hope he doesn’t mess that up.
great analogy !
@@markremillard9237 And do they actually think welding that already thin axle tube is actually going to fix the problem? The tube is still going to bend regardless under extreme weight.
@@fast460magnum5 some of these 350's approach 6 figures and this is the fix?? unbelievable
@@markremillard9237 I absolutely agree, when you’re paying that much money for a damn pick up truck and they offer you a Band-Aid. They should replace the entire axle with no questions asked.
As a welder, I can give you my simple explanation/understanding. As forward/reward torque from regular driving is put onto the leaf spring bracket, the welds on either side (at the starts/beginning/ends of welds) will be taking a lot of the forces. As the forces are applied, the welds will start to fatigue and allow slight lift/rotation of the bracket, as this fatigue increases it will put force on the tube. The tube is very strong when forces are applied/dispersed around the circumference however, as the forces are applied to smaller areas i.e. the front and rear of the bracket, the structural integrity of the tube becomes compromised as per the intended application.
The reasoning for the feeler gage is due to calculations pertaining to the structural integrity of the tube i.e. if the the bracket has lifted/rotated over a designated amount, the calculations say the tube structural integrity is compromised. If the lift/rotation is less than the designated amount, the tube is sound, and the preventive (stop the lift/rotation) measure (weld) can be taken.
Wrapping the bracket with weld in the beginning should absolutely have been done in my professional opinion. I feel for the owners who are stuck in the "wait for new axles."
-Cody
In regards to Figure 11, that is a terrible weld. I also disagree on the wire, and general set up, .045 would be ideal in my opinion.
They must have used swing set tubing.
I smell a class action lawsuit. Axle replacement mandatory.
I love spectating welding discussions. Everyone is an expert.
It's common to only weld the sides on spring perches. The perch contact area on the tube holds the weight and the weld keeps the perch from twisting on the tube. Welding on axle tubes always warps the tube as the weld shrinks when it cools. Since it's a full floating axle, Ford probably thought the warping wasn't a big enough concern but the proper way to weld an axle housing is to have a fixture to keep it straight when welding. It's seems to me that the extra welding is just a bandaid.
Engineers and welding inspectors always put that level of detail in their reports
Currently parts are not available...vehicle cannot be safely driven...please continue to make payments.
.035 or .045 is more then adequate wire size to penetrate that axle tube.
100% agree! We all know Ford doesn’t hire professional welders. What you’re getting at Ford is a mechanic that has next to no experience in “real welding”. I’m a journeyman certified Welder by the way. ✌️ I’ll be the first to say that the weld in the illustration made me cringe. 😂
@@JasonHobbsGuitarist holy crap, just got to the weld pic, I think Ford is gonna be in for a LARGE class action lawsuit over this one.
I am amazed that they are using .052 hard wire. 25-30 volts would be about 250 - 275 - 300 IPM and I'm suppose to believe every Ford dealer has a Miller 350 machine (or equivalent)? I have to agree that .035 would be sufficient Personally? I'd use .045 dual shield (I certified .045 dual shield 4G and 6G up to 1" plate) but? regardless of how much weld metal you put into the weld/repair.....it doesn't change the fact that Ford used too thin of a wall thickness for the tubes and has engineers that design by the almighty dollar, not by strength and structure. Seems that's the way of the world anymore.....design to the very minimum you can get away with.
@@GeorgiaHyway fast and hot seems to be what they’re doing … and in the process looking like shit. I’ve checked my truck too and it’s perfectly fine. No weld getting put on mine. It’s got to have some flex or guess what? It’ll crack again in the same area. Fords engineering people should know better than this and it makes them look like a bunch of a amateurs by suggesting the fix be this. Ridiculous is what it is. The stronger tubing is the only answer on a Super Duty Truck. Who they trying to fool? 😡
1. The recall applies to very low percentage of vehicles (aprox. 35k of ~1.2 million). 2. The weld is "boxing" the tube. It's common practice in civil engineering but not common in the automotive world. It'll prevent the tube from collapsing. 3. Weld procedures need to be specific. A "weld" is not JUST a "weld".
Definitely agree, all certified welds have to have a detailed procedure for every type, location, and material.
Having spent 45 plus years welding for the trucking industry I can tell you that welding the pad all the way around is a bad idea , eventually the pad will take a chunk out of the axle tube and you end up replacing the tube down the road after the recall is over .
Not gonna be Fords problem by then...they ''fixed'' it. That's the problem. They started out penny pinching, and now they have problems, so they penny pinch their way out of it.
The problem is the contact point of the spring seat to the axle is too small . I would suggest removing the spring seat and replacing it with a larger mounting surface to the axle .Spring shops deal with this all the time . It's a great time to be a welder .
Any larger contact point of the "spring seat" or base would enlargen it and interfere/hit/impede into the u bolts that are secured to the set width top plate wouldnt it or do spring shops change the whole thing ?
@@brianblithe2271 go to @6:22 the crushed area is what needs to be reinforced. on the left you can see how much you can reinforce between the u bolts . you can see on the right the spring seat is concentrating the load on the axle not distributing it .i would find a better spring seat .
@@kenreese2791 Ill take that into consideration, Thanks for reply.
The reason for checking the gap is to ensure the seat is taking the weight not just the weld area. The weld is likely more to add additional surface area but the real weight is taken by the entire seat not just the weld.
Looks like the torque of the motor under load is causing the axle housing to twist, ie the reaction of the pinion gear driving against the crown wheel. The 4 U bolts obviously cannot resist this torque putting all the force onto the Leaf Spring Bracket. Provided the gap is 0.002 or less welding should fix the problem. All replacement diffs should have this bracket fully welded, otherwise it'll happen again !!
When you drop off the truck ask the service writer for a copy of the combo mechanic / welder's cert's and an X-ray of the finished weld from a certified X-Ray company. Tell him your insurance company asked for it
LoL..
If ford actually claims work will be done by certified welders then asking for proof of that is fine. Asking for an X-ray will just get you laughed out of the building, Its a spring seat, not a nuclear reactor.
That being said ive seen some of these "certified welders" fresh out of school and their welds are horrible. I dont claim to be an professional welder myself but as a mechanic/hobby welder i can lay down much more effective not to mention nicer looking welds then many of these "certified" folks. Its all about practice, the piece of paper just proves you were taught some theory and safety practices.
If I paid $70 to $100k for a new truck, they would be replacing the entire assembly. Ford quality job 1!
Hop up the engines and weaken the axles....what could happen?
I'm not an engineer but I fail to see how that weld increases the structural integrity or load bearing capacity of the weak axle tube. I feel I now have a very expensive truck with a design flaw and a bandaid fix proposed by Ford corporate. I'm pulling a fifth wheel and even though I'm well within the load capacity (or so I thought) I now have a situation where the abuse imposed on the truck by roads, or other conditions leaves me vulnerable to a serious situation. I could've used an F250 but opted to add some safety margin by going with an F350. Did they weld/repair all the new trucks that had this flaw? No, they replaced the axles. I see a class action suit on the horizon.
I don't see how on earth welding the fore/aft end of the perch could possibly prevent the crushing failure.(?) If Ford isn't going to replace the axle it should at least engineer a proper fix, which I would think would be completely disassembling the axle and either sleeving the entire tube, or sleeving at least the top half of the tube. Also, as others have noted, I doubt the weld in the photo would pass an automotive weld inspector.
I’m pretty disappointed in their attempt at a resolution for this. Paid a lot of money for a hack weld job and a prayer.
The weld looks that way because they are afraid that the weld will blow though the axle tube
Any update on the heavy duty tremor 250’s being in this recall yet? Looks like i have the Dana 275 axle.. build March 2021
Thanks for the great video . I have a f250 tremor gasser, built inside this recall window , funny part is ,I am in the process of having a new Torque converter installed tuck only has 5000kms on it . Starting to feel ripped off by Ford .
Great Video! I completely agree with you and your analysis...specifically the two points you made. 1. Ford (actually) Dana should replace all the axle housing (axle tubes) on ALL Dana M275 rear axle housings. 2. @13:30 - you are correct.....that is not a good weld...poor weld surface attachment between the spring seat and the axle housing.
So......looks like I will need to address some things on the 2022 F350 7.3L Tremor I have coming soon. 1. The 10R140 transmission......contact Next Gen in San Diego for some upgrade parts...torque converter, clutches, etc. 2. Get the thicker walled axle tubes for the Dana M 275 rear axle. Next Gen has a very good article on the GM 10L1000.....with all the weak internal components and parts...same weak components and parts are on the Ford 10R140. Next Gen has high quality aftermarket components and parts to get both the GM 10L1000 and Ford 10R140 equipped for heavy duty work.....and greatly improve reliability, durability and longevity for both the GM and Ford trucks.
So if someone did over load the truck and deformed the tubes, this would be a way in getting a new axle?
This is completely unacceptable from Ford. No one should except this repair job. It should be a full replacement. I see a class action lawsuit coming.
I think the fix is a strategy to negate the twisting of the axle to minimize the probability that the axle with separate from the drive shaft. It also gives the lawyers a leg up on defensive motions in the future if needed. I'm not sure where this is going but we should all raise hell till they address it satisfactorily.
Ford's screw the weld repair is like pissing in the wind. The spring perch doesn't even require being welded, as the perch is sandwiched by the tube and leaf spring. The perch holds pinion angle until tightened up.
IMO, they should be fabricating a doubler shaped to the axle outer diameter and a new spring perch to fit that should be be able to rest on the new doubler. With building up the thickness, the tube won't be susceptible to crushing.
None of this inspection is checking the straightness of the axle tube. A laser light shined straight through the housing should be perfectly aligned. Just like bore alignment of a rifle scope installation. This however will require the axle shaft removal.
Dear Gunga Dinn: The perch has to be welded lest the entire axle would twist inside the clamping devices. Think, think: big high torque diesel engine, torque multiplied with the trans in low gear, then that torque again multiplied by the rear axle ratiio (possibly a 4 to 1 ratio). Not welded, really. I've adapted several different axles into different vehicles into which the axle didn't belong and always welded the spring perch, it's a requirement.
The fix is call ECGS.
Disappointed I'm just seeing this now. Just picked up my 2021 6.7L F350 Super Duty Tremor on Saturday. The dealership told me there was a recall that needed done on the axle before I could pick it up. They said it was something about checking a weld. Made the purchase this past Thursday. The dealership then told me the recall was rescinded on Friday but couldn't provide any paper like in the links above, so they printed out the Oasis system report on my VIN and it doesn't show any recalls. To top that off, the front passenger wheel started squealing like crazy yesterday morning so now I'm off to the repair shop in a couple of hours. I'm feeling like I got taken.
It’s insane to have random welders repairing a life and death component without apparently even doing proper preparation
That's huge wire size.
They want to take care of this issue with a single pass repair, minimizing heat saturation..
Is this going to expand to F250 Tremors 6.7? Or do we have different axles? How do I know what axle got out on my truck? Truck Build is March 2021
Ford has lost my trust because of this, and also many other faulty design issues I've seen. When I buy my next truck, it will not be a Ford, unless they do a complete 180 on their strength and quality.
Interesting that there is no mention of ubolt torque. Loose ubolt's will contribute to axle wrap, which is what's causing the tube deformation.
My guess is it’s a torque related issue on the tubing. That would explain why the F250’s are not needing a repair or new axel. Nothing to do with weight on axel.
Did not know you could fix a broken arm with a bandaids
Too thin saved by magic weld? I think not.
What if they tell us they can only weld it due to the rules Ford has set? Do we have the right to request full replacement?
Looks like the lube tech made that weld in the picture of the recall bulletin 🤣
Yf
For over 60 years, Ford has been using their customers to do the proper engineering on their vehicles.
And still don't know how to build a diff
Honestly, who in heck ever heard of an axle collapsing on a brand new F-350 (built Ford tough) Super Duty? With a diesel this is at least a $65,000 truck, this is an unconscionable engineering failure on the part of Ford! Then to come up with this Micky Mouse fix (sorry Micky), is insulting to anyone one who knows anything about drivetrains. That welding job is a joke, you'll probably get bearing arc unless you take the differential completely apart and run the risk of warping the already compromised axle tube. That spring seat is there primarily to position the pinion angle so the u-joints don't fight each other and to steady the load from above. This is what happens when truck companies are run by accounts and milk every cent out of their suppliers by opting for substandard components and spending that money on advertising. Like Ron said, "you can't fix stupid"!!
WAS made by DANA CORP
@@johnbell238 No doubt, but it's Ford's responsibility through quality control and monitoring it's supply chain to make sure they don't T-bone their customers with substandard components or "substitutions" with parts that amazingly have the same assembly code. This often happens at the behest of accounting department interventions circumventing and compromising engineering/operations which all of the US builders have been guilty of.
Remove the stock seat from the top of the axle......get a piece of channel the full length of the axle tube clamp it in at the ends put new longer U bolts.... no welding required... and a lot cheaper than a new axle
Kinda had the same thought as well when I herd about this issue and the shitty fix they came up with. Although I think they would probably still need to weld it to the axle it would still be a better fix than what they are suggesting.
When can we bring manufacturing back to the US? That will solve a lot of problems, understand the axle tube are from overseas.
Can’t wait for the accidents to start in a few years after this silly quick fix fails - ahh ford I plan to see ya in court
They are using the weld to distribute the load over a bigger area. It l may help a little, but to me this is just buying time.
If the truck is used @ near its maximum load, the welding will not help.
To crush like that means the tube is way under strength. Adding a few % to the load area is not going to solve the underlying problem.
Thank you for this important information.
I don’t think the purpose of the weld it to prevent the crushing, I think it’s to reduce the odds on driveshaft separation and crashes as a result. Pretty much a band aid to reduce lawsuits for death or injury.
You would think Ford would have plenty of axles laying around the factory since they can not build new trucks because of the “chip” shortage. It’s getting to be embarrassing to own a Ford truck lately
I would be embarrassed of any year ford.
@@alaskarailroad3996 haha, you funny. Please don’t tell me you drive a RAM 😳
What's the wall thickness of those axle tubes
Looks to me like the axle tube thickness is sub par. There should never be a tube crush like that. Been a Ford man all my life till just recently. You couldn’t give me one now. Such a shame. The company is killing itself slowly.
You know,i agree.Im also a Ford guy(im 66),and just disappointed in everything coming out of Ford lately.I did bite the bullet and got a 2020 Fusion after my retirement,and like it so far,and ill never sell my 95OBS 7.3PSD.I want it buried with me.But being a fan of the BlueOval isn't what it used to be.smh.
ALL manufacturers.....Ford, Chevrolet, GMC, Dodge (Ram / Sheep), Nissan and even Toyota have quality issues and problems. People should take some time and read on the Chevrolet / GMC and Dodge truck forums. GM is having countless quality issues and Dodge is just as bad, maybe worse.
It is a VERY competitive market and EACH manufacturer faces producing a competitive product at a cost that yields a profit weighed against cost of expected / potential warranty claims. EVERY manufacturer uses cheap inexpensive components and parts often designed to last just beyond the standard warranty period.
Regarding Dodge trucks. It is absolutely shameful that executives implemented the brand name change back in 2009 - 2010. On a few fronts, it was an idiotic and stupid decision. It would be like Ford changing the name of their trucks to Edsel.
They should have kept the Dodge name. They messed with the heritage and legacy of the Dodge name..."The Dodge Boys" - brothers John and Horace. In addition, they messed up the heritage and legacy of the DODGE Power Wagon. Besides, the Ram brand name was a poor choice even if it had been used previously as a "model name" for the Dodge trucks. The Ram name makes me think of Sheep.....not a good name for a truck.
You would think Ford would use a better looking weld for an example. I'm not a pro welder, but my welds look better than that. If this only affects 20 & 21 F350's what makes the 2019 and back models OK? What did they change ? Thinner tubes to save a buck would be my guess.
Ford isn't the one doing the weld, that would be Dana and they are under ram as well
@@bradsmith5838 From the way I saw it, Ford is telling the Dealers how to repair it by rewelding as shown.
@@bradsmith5838 ram no longer uses dana in they're heavy duties they use american axle
Fix and repair daily!
FARD...??
I guess it depends on what part of the country you live in BCelectric LOL
The welding fix seems to be a feel good stop gap fix. We don’t have parts for the proper fix so we’ll make the owner feel good that we did something.
May be the weld will help slow the damage (till it’s out of warranty)….
Seems to me a larger surface area for the leaf spring seat bracket would hold better. Such as the pad wrapping further around the shaft. Also notice how much wider the bottom support bracket for the u-bolts are.
Yea it would seem like spreading out the downward force more would be better. Apparently they think it's the wrapping/twisting motion though?
Since there is no parts available, is Ford gonna pay all the people that use these as work truck for lost wages and time and revenue? Huge oversight making an axle tube so thin it crushes. I've see Toyota trucks form the 90's yes the small ones carry way more than they should all the time and no axle crush.
Is painting the axle part of the recall?
Thanks for the info
Any time!
Everyone take note. Ford doesn’t make these axles. The f-250 with out heavy tow package has the standard sterling 10.5 they have had since 99. The f-350s single rear wheels with the diesel come with the DANA M275. I know this because I own one. They are made by Dana. HOWEVER it doesn’t excuse fords BS response. Personally I have always driven fords, but my parents had a f-150 with a 10 speed that was never right. I had a 2019 f-350 which suffered through multiple warranty claims. My trust in ford is lost. This is not your dads old 7.3 powerstroke. These are manufactured for the lowest possible cost.
Made by Dana to Fords specs, it looks like a combo of CFCS (Cheap Frigin' Chinese Steel) and the wall thickness is to thin, (GVT mandated millage requirements.)
@@SegoMan Do these Class 2 and Class 3 trucks have government mandated fuel mileage requirements? No city and highway mileage posted on the MSRP's.
Great Comment! Your last statement says volumes regarding cost, competition and most important...quality of components and parts.
However...and just an FYI...the 10.5 axle is NOT a "Sterling axle". There is NOT a "third party company" named Sterling manufacturing axles for Ford. Instead, it is a corporate axle...made by Ford Motor Company...at the Ford axle plant located in Sterling Heights Michigan.
The 10.5 axle has mistakenly taken on the "Sterling name" most likely because Ford executives, management and employees refer to the plant as the "Sterling axle plant"...BUT, that does not make it a "Sterling axle".
It appears that numerous internet posters incorrectly used the Sterling name years ago...and unfortunately the incorrect name stuck.
Missed it by 4 days!
I am a retired hdr mechanic welder local 12 operating engineers union ... And i agree whith you on the reason of welding displacing the load . But it is a bullshit idea if the tube is too thin nothing will fix it but replacement of the inferior tube . I find it ironic that ford has such a collosal fuck up , whith no parts to replace it whith . Especially after ford pissed off navister whith their own diesel engines violating the contract whith international causing us to nolonger get parts for international engines . I hope ford takes it in the ass as hard as we do for owning their trucks whith now obsolete engines
$100000 truck and they want to bandade it i don't think so the weld will not stop the fexing if anything create pinch point and crack over time
Can't drive your truck.? So will they refund for lost income caused by having the truck down. Hopefully the loaner truck is an equal truck
Still waiting on month two now for a replacement tremor tire. Good luck getting axles replaced.
I dodged a bullet my 350 was made a month after the date and is a 6.2 gas
I'm glad mine has the Sterling :D
That's an ugly weld. The reason for changing grounding positions is to keep it from arcing through the bearings. You want to keep the ground close to the weld area as possible. Have seen the results of arcing through the bearings. Have to replace all the bearing. In a diff. It will also ac between the ring and pinion too.
So…. Why is it only F350 SRW Diesels…. Why not F250 with diesels and tremors with diesels…. I know we are all speculating they are next on the recall but come on Ford! New axles for us all who need it is soon to come once the law suits start.
To be fair the 250s have the old sterling 10.5 axle. The 350s have the “newer” Dana m275
@@paulj9375 what about the 250 tremors?
@@tcr2237 I’m not entirely sure because it likely auto includes may other packages from the factory. I know on the gas models they only come with 4:30 gear ratio
Sure weld all around the perch and guaranteed the whole thing blows out instead of crushing and cracking Guaranteed! Oh sorry we don’t have parts to fix our f up so your SOL ! Thanks Ford !
these axels are not made by ford.
Built by Dana to Ferd specs..
I think welding is a waste of time and yes im a ford guy.
And the poor Phord engineers screw up once again. What were they thinking?
That weld is garbage and I don’t see how it actually fixes the REAL problem. I have a 04 (that’s paid for yaay) and I’ve never had any issues with the Sterling 10.5. I know the newer trucks have way more power and tow a heck more weight, but I tow a 20k 5er, 2-5 thousand miles a year, tuned so she puts out decent torque numbers. Not sure why Ford stopped using the Sterling units. I’ve heard nightmare stories of open Dana units sitting at Mexican seaports rotting from the salty ocean air, waiting to be shipped to the US. Dodge had a bunch of bearing issues in the early 2000’s because of that scenario. QC is obviously an issue @ Dana.
I had an obs f250 with the 10.25 I believe. Tough truck but also like you say it didn't make barely half the power even with a tuner than the new diesels. I have a dana 80 in my f450 dump truck and dodge 3500 and pushed the f450 to the limit. It makes even less power with the 7.3 IDI but 6 tons in a 9600lb truck is a lot when it has a GVWR of 14.5k. Axle rating in that truck is 11k or 12k thought.
You are fucking crazy that this is the fix.....they are welding perches where they never have been welded to make a band-aid!....these aren't failing because of weight its because of the torque of the housing trying to spin...thats why they have them check with a feeler guage to see if it started to happen yet....BTW if I got my truck back with a weld that looked like that I would leave it there.....are they expecting a normal tech to have the knowledge of how to do the weld correctly?. Just because it's welded doesn't mean it's right......this whole thing is ugly on ford's part
That was a weld ,,,I think they put a bead of caulk on it 😁
A grinder and thick coat of paint, makes me the welder I ain't!
That figure 1 is from a 2021 truck?? Lol
I hope welders do a better job than what the bulletin shows. A 3rd grader can do a better job than that.
the comments are mostley wrong this axle was not made by ford but will be fixed by them tpp many arm chair welders here.
Built by Dana to Ferd specs..
I would not trust a Ford dealer (or any non commercial OEM truck dealer really) to weld a mud flap bracket back on let alone weld on an axle housing. Plus the weld only fix seems incredibly half ass with no gussets or plating.
I guess the plan should be inspect your axle yourself and if it fails load up to max payload and start doing full torque throttle rolls ons and brake-torques all the time until axle is crushed lol.
That weld is nothing but mud. No penetration on too thin metal.
Fix Or Repair Daily.
So it would seem there has been a miracle! After the dealership told me my Axel has failed and my truck is unsafe to drive; now only 2 days later, my trucks Axel is now a pass and safe to drive! They will be conducting the weld, even though I am pushing back and requesting the Axel as promised! I am speaking to Ford directly…nobody cares! So NOT impressed with Ford. I wish we could all get together and force them to do the right thing!
I was planning on buying a new 2022 F250 Super Duty. Now, I might buy the new Toyota Tundra or Ram.
I know a few chicks that drive those trucks, no biggy
Why? The axles are no longer being made this way, and it wasn’t a Ford problem in the first place. Dana changed their procedures without notifying Ford, check out the other video. I imagine this recall is costing Dana a pretty penny.
You did not mention engine choice for the 2022 F250 SD truck...6.7L diesel or the 7.3L gas??? Virtually every manufacturer is having issues, problems and recalls.....on a variety of things regarding weak parts, and china made electrical and computer components and modules.
Next Gen in San Diego California has high quality aftermarket parts (torque converter, CNC machined aluminum billet pistons, stronger CNC machined aluminum billet Stators, additional STEEL clutches, etc.) for the 10R140 transmission...to "bullet proof" the transmission. Some F250 (NON Tremor) SD trucks come with the Ford 10.5 rear axle. If you get the Tremor Package, both the F250 (Class 2 ) and F350 (Class 3) will have the Dana M275 rear axle.....which is the axle with the problems in this video. The permanent fix is to replace the LH and RH axle tubes (axle housing) with the new part number that has thicker wall tubes.
The new multi speed transmissions are very complex. I would bet a fair amount of money there are NO aftermarket upgrades for any of the Toyota (Class 1 - 1/2 ton trucks) automatic transmissions...and doubtful about any for the newest Dodge (Ram) trucks...however, probably forthcoming. There are plenty of aftermarket upgrades for the older automatic transmissions for all of the Big 3...Ford, Dodge and GM. Maybe I am wrong, but the fact that you even mention the Toyota truck.....tells me that you do not even have a need for a Ford Super Duty....or a GM Heavy Duty or Dodge Heavy Duty truck.
Ok well you obviously dont need a truck if going with tundra !
I was a FORD guy but just bought a Ram 2500
Very poor weld. Glad it is not my truck!!!
Looks like a bunch of Lawyer shit.
The weld in the picture is laughable. I can't believe they used that as an example photo for a major auto manufacturer instruction example. Makes you wonder who at Ford has any common sense. If the tubes are that thin to start with this is not going to help enough anyway.
First off, that's a bad looking weld, second, you should never DC arc weld on something that has internal ball or roller bearings because of what is called bearing arc. I arced a ball bearing and it wasn't a pretty sight nor was it cheap to fix. The differential should be completely disassembled and cleaned inside and out before welding.
Nice video!
I have a 2021 F-350 7.3 . Doesn’t my truck have this axle ? Why just 6.7’s? Confused 🤔
Probably because only the 6.7
Has enough torque to break it. Fords logic. 😐
@@jsboening The payload in the bed is more in the gasser 7.3 I believe?
@@roadglide1142 I believe the torque that the diesel puts on the rear end is the problem. As the engine applies torque to the rear end it wants to rotate the front of the rear end down towards the ground. It’s the twisting force that sets the tubes demise in motion not the crushing force from the payload. Who knows maybe gassers will be next in line.
2.5 times the torque thats why ...those 6.7 are crazy power and torque compared to a gasser
The weld in the Ford Instruction Bulletin is sub-standard and would not pass a weld test buy an AWS inspector. My personal opinion is that the load on the axil has little to do with the crushed condition of the axil at the spring seat. I would say the compressive force of the U-bolts tightened to the spec of 195 ft/lb is far greater compressive force on that area of the axil than the weight of the truck and load on the truck. The reason I'm saying this is that folks are chiming in on various on line conversations indicating their axil looks compressed and has paint chipping off the axil at this location on brand new trucks that have not even had a load on the truck yet. It's also being noticed by both 6.7 and 7.3 owners. My 7.3 F350 Tremor has signs of crushing and it's 3 months old and never carried a load to date.
Odd that your 7.3 shows signs. My 6.7 that's pulled a 5th wheel with 3K lbs pin weight and 15K lbs towed 11K miles in the last 7 months seems to be fine (visual inspection). However, under heavy acceleration I do feel driveline shudder. Has me a bit worried.
@@skremese Exactly and that's my point. The axle deformation is originating at the factory during install. The reduced tube wall thickness combined with the torque on the U-bolts is deforming the axil, and that's why folks are finding their new truck off the lot with paint chipped off the axil between the u-bolts. The axle twisting under heavy acceleration and load with the 6.7 is tearing the welds loose over time and causing the secondary symptoms you are experiencing. There is actually two problems that are occurring in succession and both the 7.3's and 6.7's are susceptible. The first happens at assembly and the second occurs in daily usage.
everyones an expert🤣😂🤣😂
@@steveschilling5966 OK, so what's your take. As a fabricator/certified welder and machinist that was my take.
@@chrisneuhaus7188 Do you think that their weld "hotfix" is acceptable? I know that everyone is saying how crappy it is but I guess it makes sense than a sub-par/small weld on both sides wouldn't be nearly as strong as a 360 degree weld. If the thing that breaks first is the weld, perhaps fixing the weld would help?
On the other hand, they are fixing the issue on new ones by going to a thicker axle, so obviously they do think that that's the better solution.
A lot of recalls on these superduty 1 tons cant imagine a used one having dogshit value for a trade in a few years from now . Im keeping 2004 gmc 2500hd till it dies a mega death
Just add some weld, help get it out of the 36 month ,36,000 mile warranty then it is not their problem. Ford saved a little weight and money making the axles tubes thiner.
This is why my recent strategy has been to buy them new and sell them before 30k miles
That's an ugly weld. This will not be a correct fix. Ford needs to buy these trucks back if they don't have axles. Sounds like a big lawsuit coming.
I wouldn’t stand for that. Trade it off……I would guess that there will be a ton of F350 single rear wheel trucks on dealers lots for sale on the used market.
This is a Dana issue Dana is covering this cost and paying for the repair of those affected. It is the front axle and has a poor quality weld on it .
This is for the rear axle.
@@BigBoyToyzz it is not a ford Sterling Axle. It is the Dana axle
@@tedborgers3276 the recall is the rear axle!
Built by Dana to Ferd specs..
Yes but dana deviated from the prints and specs
Ford sucks so completely…I bought my new 2020 F350, and my first I might add, specifically to carry a new Lance camper after much research on payload capacity and capability. Then I get a recall notice that they overstated the payload capacity and the fix is a new f$k/@n payload sticker! WTF! And now this friggen recall!! And their fix is to remove my entire rear end, do some hack weld job and attempt to put it all back together again?! I paid very large sum of money on what they advertised and it turned out to be a complete sham not to mention what I paid for in the new camper this truck was advertised to carry! What a sorry and dishonest company you are Ford Motor Company, I will be joining that class action!
This is what happens when you buy new. Which is why I prefer buying a few years older. This kind of thing will happen with any brand that chunks out something new.
@@mmardell9262 I hear that and thought I might be avoiding that with a late year build 2020 just before 2021 but that didn’t make a difference unfortunately. Its actually a shame that we can’t trust what they are putting out into the market as new. And yes, all of the brands have recalls for sure, not just picking on Ford here but unfortunately these last few recalls (new transmission recall in there as well) from Ford are pretty damn serious and far beyond what should be piling up at this stage…somebody has taken their eye off ball at Ford no doubt as they are busy trying to rush a ton of new vehicles to market (can only imagine what recalls those vehicles get hit with!). E
@@RT-fy7gt in all honesty most if not all companies don't care about us. They only care about our money. If they do happen to acknowledge our existence, it's usually because we are a potential buyer, and/or and existing one with potential lawsuits.
So they’re sending known unsafe parts back onto the road because they had some hack at a dealer use a welder on it having had no formal welding training? Sounds like a perfect FORD fix! Lol what a joke.
At least they recalled they're still built better than a Chevrolet🤣🤣😍😍
Chevy wouldn't recall this problem, they don't give AF.
Not true im a ford guy I own a f150 but my mom and my friend both own chev . One is a suv one is a truck . Both needed engine jobs after warrenty ( no warrenty left ) both burning oil and having troubles which chev is famous for . Chev replaced both engines free because they got regular oil changes . Is chev junk.. the answer is yes .. does chev recognize this .. yes they do and they go above and beyond to fix it so I have to disagree with this comment.
I'm very disappointed with ford on these new 2021 f150s . That axel tubing is wayy too thin regardless and rusting like crazy very fast . These axels are not going to hold up for years to come with salt roads etc no matter what you weld or do it simply is a design flaw with garbage steel . The only true way to fix this is new designed rear axels with thicker better quality steel but ford can't do that because of the loss they have taken on the trucks that can't he sold sitting on lots waiting for parts . These trucks that are sitting there are having major issues the axel is the least of its worrys . Engine seals on the engines are not being lubed properly from sitting there rodents are going up inside and chewing wires . These trucks are on a lot packed in like sardines and are basically getting destroyed by sitting there a new engine needs oil lubrication to keep all seals in working order. Ford is losing there shirts on this because people are starting to figure this out via social media and RUclips. Ford and other companies are actually in a mess because of this right now but ford being the worst because being a new generation 2021 it also has other issues rusty soft thin rear axels and whatever else. What a mess .. trying to fix this issue with weld is a disgrace and an embarrassment for any ford owner or fan . DO NOT SETTLE FOR A WELD. this is wrong in so many ways you can not sell a new truck and then grind and weld the rear axel and send it back on the road. Yes ford is in a crisis with these f150s in many ways but that will only cause more chaos in the end . New designed rear axel is the ONLY proper fix . Be careful if your buying a new 2021 and up f150 check the build dates if it was a truck sitting on the lot waiting for parts DO NOT BUY IT ford is trying to keep this quiet but biggggg problems with these trucks that sat in the lot a new truck is not suposed to be built not fully assembled abs sit in a lot for months with no emgine start up or being moved this is not how it goes tgis is only because they had no choice . Who's going to suffer from this?? Anyone who buys one of those trucks that had to wait for parts . The consumer not ford from what I can see from this video ford will do a half assed fix and as long as it works itl be your problem .