My thoughts on CV axles - possible design flaw? (self replacement, tear down, tips on DIY-ing)

PNWMaverick said:

There is a thread on here addressing the design flaws of the CV axels and options to fix it via aftermarket manufacturers that have agreed to make them. Enough people have had issues that some industrious person went out to find replacements. Here is to hoping Ford figures it out on their own.

Click to expand...

EM33 said:

Excellent writeup, bookmarked.

Sucks about the ball joints, that turns a $75 repair into almost $500. Looks like the control arms are ~$250 each...

https://parts.lakelandford.com/p/Fo...--Rear--Upper--Lower/105733943/LX6Z3078H.html

Click to expand...

801Maverick801 said:

2022 FX4, 4k tow, 28k miles, 1 inch rough country leveling kit on front suspension, 1.5 inch Eibach rear springs.

The truck started to get a slight rumble at close to 20k miles, after reading online about the CV axles, I knew this was the issue. I waited hoping Ford was going to issue a TSB or recall and a year went by and the rumble was getting worse and worse. A few weeks ago I took some friends golfing and had 5 people in the car and the bed loaded up. Upon accelerating up a hill, the truck was shaking so bad, steering wheel and whole front end was shaking back and forth in sync with depressing the throttle and I decided I needed to swap them.

Decided to do this myself to try and figure out why this is happening to so many Mavericks, the Axles are cheap, and I have serious trust issues with other people touching my vehicles (14 year Aircraft mechanic).

After replacing the axles, my truck literally drove like brand new again, I couldnt believe how bad the rumble had gotten and how used to it I was.

art Number​	Part Name​	Price​	Quantity​	Total​
nz6z3b436b​	Axle Assembly​	$111.98​	1​	$111.98​
NZ6Z-3B437-C​	Shaft Front Axle​	$113.63​	1​	$113.63​

Subtotal: $225.61​

Estimated Shipping to 84111 via Standard Shipping: $58.61​

Tax: $16.62​

Discount: -$11.28​

Total: $289.56​

Total from Tasca parts online.

I think the problem is the Right Hand Axle with the female spline on the inboard axle. This was the only axle I could feel by hand that had play, it was wobbly when I grabbed and shook it (radial play) while it was installed on the truck. Looking at the splines, it has 2 splines that dont exist, I have no idea why they would do this, there is no master spline on the male end coming out of the PTU, the Male end is fully splined. With the 2 splines missing, I think its more susceptible to increased wear from vibration. The new Axle also came with the female spline with big gaps 180degree out.

Wear on the inside of the Inboard female spline housing

When this happens again, Im only going to replace the Right hand axle and see what happens.

TIPS ON REPLACEMENT

I know alot of people might be out of warranty and looking to do this yourself, Its really not that bad if you dont follow the Ford Manual (LOL)

Ford manual wants you to disconnect the lower control arm, good lucking getting the lower ball joint out. The lower ball joint is one of the worst designs ive ever seen and as far as I can tell, its not replaceable, you have to replace the lower control arm as a whole. Do yourself a favor and spray rust prevention on the lower ball joint right now for the future, there is a recess in the Lower control arm at the top of the ball joint where salt/water can accumulate and form rust. I modified a tie rod splitting tool to make it work but decided to remove the knuckle from the strut instead. There is very little room for any leverage, if the vehicles on a lift you could more easily remove the lower ball joint

How I found it easy to replace the Axles.

-Break lugnut/Axle nut torque on the ground. (deep 32mm for Axle nut)
-Disconnect Tierod
-Disconnect ABS wire supports
-Disconnect upper sway bar link (you will need to jack up lower control arm to relieve pressue on Sway Bar)
-support knuckle with cam strap to strut
-Disconnect and hammer out both Strut Bolts
-Hammer Axle in hub to loosen bond in wheel bearing(dont damage threads)
-Pry between transmission housing and axle housing to defeat circlip on Axle (I hope your strong, will take all your body strength)

Plan on having 2 quarts of ULV ATF on hand, I lost about a quart on the left hand side after pulling the axle.

I can do each side in an hour now, really not bad.

I really hope Ford figures this out, its not a big deal for me if I have to do this every couple of years for not that much $. But I understand for most people that have to pay for this to be done, the cost can be brutal. I am guessing this will be well over 1000$ to have the dealer do this?

MISC Torques

-Lugnuts 150 lb Feet
-Axle nut 76 lb Feet + 45degrees
-Strut to Knuckle bolts 103 lb Feet + 120degrees
-Upper sway bar link 81 lb feet
-Tie Rod to knuckle 35 lb feet

Click to expand...

801Maverick801 said:

2022 FX4, 4k tow, 28k miles, 1 inch rough country leveling kit on front suspension, 1.5 inch Eibach rear springs.

The truck started to get a slight rumble at close to 20k miles, after reading online about the CV axles, I knew this was the issue. I waited hoping Ford was going to issue a TSB or recall and a year went by and the rumble was getting worse and worse. A few weeks ago I took some friends golfing and had 5 people in the car and the bed loaded up. Upon accelerating up a hill, the truck was shaking so bad, steering wheel and whole front end was shaking back and forth in sync with depressing the throttle and I decided I needed to swap them.

Decided to do this myself to try and figure out why this is happening to so many Mavericks, the Axles are cheap, and I have serious trust issues with other people touching my vehicles (14 year Aircraft mechanic).

After replacing the axles, my truck literally drove like brand new again, I couldnt believe how bad the rumble had gotten and how used to it I was.

art Number​	Part Name​	Price​	Quantity​	Total​
nz6z3b436b​	Axle Assembly​	$111.98​	1​	$111.98​
NZ6Z-3B437-C​	Shaft Front Axle​	$113.63​	1​	$113.63​

Subtotal: $225.61​

Estimated Shipping to 84111 via Standard Shipping: $58.61​

Tax: $16.62​

Discount: -$11.28​

Total: $289.56​

Total from Tasca parts online.

I think the problem is the Right Hand Axle with the female spline on the inboard axle. This was the only axle I could feel by hand that had play, it was wobbly when I grabbed and shook it (radial play) while it was installed on the truck. Looking at the splines, it has 2 splines that dont exist, I have no idea why they would do this, there is no master spline on the male end coming out of the PTU, the Male end is fully splined. With the 2 splines missing, I think its more susceptible to increased wear from vibration. The new Axle also came with the female spline with big gaps 180degree out.

Wear on the inside of the Inboard female spline housing

When this happens again, Im only going to replace the Right hand axle and see what happens.

TIPS ON REPLACEMENT

I know alot of people might be out of warranty and looking to do this yourself, Its really not that bad if you dont follow the Ford Manual (LOL)

Ford manual wants you to disconnect the lower control arm, good lucking getting the lower ball joint out. The lower ball joint is one of the worst designs ive ever seen and as far as I can tell, its not replaceable, you have to replace the lower control arm as a whole. Do yourself a favor and spray rust prevention on the lower ball joint right now for the future, there is a recess in the Lower control arm at the top of the ball joint where salt/water can accumulate and form rust. I modified a tie rod splitting tool to make it work but decided to remove the knuckle from the strut instead. There is very little room for any leverage, if the vehicles on a lift you could more easily remove the lower ball joint

How I found it easy to replace the Axles.

-Break lugnut/Axle nut torque on the ground. (deep 32mm for Axle nut)
-Disconnect Tierod
-Disconnect ABS wire supports
-Disconnect upper sway bar link (you will need to jack up lower control arm to relieve pressue on Sway Bar)
-support knuckle with cam strap to strut
-Disconnect and hammer out both Strut Bolts
-Hammer Axle in hub to loosen bond in wheel bearing(dont damage threads)
-Pry between transmission housing and axle housing to defeat circlip on Axle (I hope your strong, will take all your body strength)

Plan on having 2 quarts of ULV ATF on hand, I lost about a quart on the left hand side after pulling the axle.

I can do each side in an hour now, really not bad.

I really hope Ford figures this out, its not a big deal for me if I have to do this every couple of years for not that much $. But I understand for most people that have to pay for this to be done, the cost can be brutal. I am guessing this will be well over 1000$ to have the dealer do this?

MISC Torques

-Lugnuts 150 lb Feet
-Axle nut 76 lb Feet + 45degrees
-Strut to Knuckle bolts 103 lb Feet + 120degrees
-Upper sway bar link 81 lb feet
-Tie Rod to knuckle 35 lb feet

Click to expand...

801Maverick801 said:

2022 FX4, 4k tow, 28k miles, 1 inch rough country leveling kit on front suspension, 1.5 inch Eibach rear springs.

The truck started to get a slight rumble at close to 20k miles, after reading online about the CV axles, I knew this was the issue. I waited hoping Ford was going to issue a TSB or recall and a year went by and the rumble was getting worse and worse. A few weeks ago I took some friends golfing and had 5 people in the car and the bed loaded up. Upon accelerating up a hill, the truck was shaking so bad, steering wheel and whole front end was shaking back and forth in sync with depressing the throttle and I decided I needed to swap them.

Decided to do this myself to try and figure out why this is happening to so many Mavericks, the Axles are cheap, and I have serious trust issues with other people touching my vehicles (14 year Aircraft mechanic).

After replacing the axles, my truck literally drove like brand new again, I couldnt believe how bad the rumble had gotten and how used to it I was.

art Number​	Part Name​	Price​	Quantity​	Total​
nz6z3b436b​	Axle Assembly​	$111.98​	1​	$111.98​
NZ6Z-3B437-C​	Shaft Front Axle​	$113.63​	1​	$113.63​

Subtotal: $225.61​

Estimated Shipping to 84111 via Standard Shipping: $58.61​

Tax: $16.62​

Discount: -$11.28​

Total: $289.56​

Total from Tasca parts online.

I think the problem is the Right Hand Axle with the female spline on the inboard axle. This was the only axle I could feel by hand that had play, it was wobbly when I grabbed and shook it (radial play) while it was installed on the truck. Looking at the splines, it has 2 splines that dont exist, I have no idea why they would do this, there is no master spline on the male end coming out of the PTU, the Male end is fully splined. With the 2 splines missing, I think its more susceptible to increased wear from vibration. The new Axle also came with the female spline with big gaps 180degree out.

Wear on the inside of the Inboard female spline housing

When this happens again, Im only going to replace the Right hand axle and see what happens.

TIPS ON REPLACEMENT

I know alot of people might be out of warranty and looking to do this yourself, Its really not that bad if you dont follow the Ford Manual (LOL)

Ford manual wants you to disconnect the lower control arm, good lucking getting the lower ball joint out. The lower ball joint is one of the worst designs ive ever seen and as far as I can tell, its not replaceable, you have to replace the lower control arm as a whole. Do yourself a favor and spray rust prevention on the lower ball joint right now for the future, there is a recess in the Lower control arm at the top of the ball joint where salt/water can accumulate and form rust. I modified a tie rod splitting tool to make it work but decided to remove the knuckle from the strut instead. There is very little room for any leverage, if the vehicles on a lift you could more easily remove the lower ball joint

How I found it easy to replace the Axles.

-Break lugnut/Axle nut torque on the ground. (deep 32mm for Axle nut)
-Disconnect Tierod
-Disconnect ABS wire supports
-Disconnect upper sway bar link (you will need to jack up lower control arm to relieve pressue on Sway Bar)
-support knuckle with cam strap to strut
-Disconnect and hammer out both Strut Bolts
-Hammer Axle in hub to loosen bond in wheel bearing(dont damage threads)
-Pry between transmission housing and axle housing to defeat circlip on Axle (I hope your strong, will take all your body strength)

Plan on having 2 quarts of ULV ATF on hand, I lost about a quart on the left hand side after pulling the axle.

I can do each side in an hour now, really not bad.

I really hope Ford figures this out, its not a big deal for me if I have to do this every couple of years for not that much $. But I understand for most people that have to pay for this to be done, the cost can be brutal. I am guessing this will be well over 1000$ to have the dealer do this?

MISC Torques

-Lugnuts 150 lb Feet
-Axle nut 76 lb Feet + 45degrees
-Strut to Knuckle bolts 103 lb Feet + 120degrees
-Upper sway bar link 81 lb feet
-Tie Rod to knuckle 35 lb feet

Click to expand...

801Maverick801 said:

It should be illegal for a manufacture to make a Ball Joint an unreplaceable item by itself.

Click to expand...

scottp01 said:

Holy shit, that is ridiculous! My $16k Fiesta had ball joints that were a separate piece. There is no reason a $30k truck built for mild off-road use shouldn't have replaceable ball joints!

Click to expand...

scottp01 said:

Please report to the NTSB about these axle issues. The more people that complain, the more likely they are to force Ford into doing a recall and developing a proper fix.

Ford is trying to put the blame on lift kits, but people on stock lifts are running into issues. Lots of dealers are ignoring the issue, hoping that by the time they fail that the owner is out of warranty. Some are taking out the transmission when they finally go.

Its obvious from your teardown that there's an inherent design flaw that should be addressed.

Click to expand...

PNWMaverick said:

Here is to hoping Ford figures it out on their own.

Click to expand...

801Maverick801 said:

Just submitted.

Click to expand...

801Maverick801 said:

Thats funny because I was just looking at a Focus that has the one bolted onto the lower control arm with 3 bolts, easy to replace. Its basically the same aluminum lower control arm but now without an easily replaceable Ball joint. Utter Bullsh** to squeeze more $$$ along the Maintenance side.

Click to expand...