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

[new to maverick]

at 28K miles isn't this under warranty?

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[801Maverick801]

I worked at a Chevrolet Dealer for 22 years. Aftermarket suspension lifts and lowering do in fact cause things to fail prematurely. Talk to an engineer if you don't understand this, but it's probably more like you don't want to understand this and just put the blame on Ford.

If you follow anything Maverick at all, you will know these are failing at high rates on non-modified trucks. Ive lifted multiple vehicles much higher than my 1 inch lift, and never had axle issues like this. If you know vehicles at all, you wouldnt be siding with Ford.

 

[Duke Nukm2001]

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

Thank you for the Pictures and the walk-through.

 

[Montana]

I worked at a Chevrolet Dealer for 22 years. Aftermarket suspension lifts and lowering do in fact cause things to fail prematurely. Talk to an engineer if you don't understand this, but it's probably more like you don't want to understand this and just put the blame on Ford.

You realize this is happening with stock setups too, right?

It's a design flaw.

Yes, shitty lifts and lowering kits like OP's cause problems. Changing the angles will cause premature wear one way or another... but this is happening on stock Mavericks both Hybrid and EB's. I don't doubt that OP's puck kit accelerated it, but the fact remains that it does still happen on stock setups regardless. Reports on this forum from people who have done zero modding are having this issues - some multiple times even after having them replaced.

Having my CV axels replaced today. The dealership has had my Maverick the previous two days as well for recall work. They just texted me a moment ago they also want to replace my driver's side axel shaft because there still getting shaking while accelerating. This truck is starting to piss me off, lol.

Are you at stock height? Any modifications done?

 

[bgn]

What did you submit? That you modified your vehicle beyond OEM spec and there was a failure......

Alright, I won't submit one for the failure on my stock Maverick. It evens out.

 

[bgn]

at 28K miles isn't this under warranty?

It's covered for 5 years/60k under the powertrain warranty. If a lift is installed, they may or may not warranty it.

 

[bbhaag]

Alright, I won't submit one for the failure on my stock Maverick. It evens out.

Alright, then start your own thread about it but right here right now in this thread the OP modified their vehicle beyond OEM spec which should not be submitted as a factory safety defect.

 

[StevenC56]

If these are failing on unmodified vehicles that have no signs of abuse or failure due to outside influences, then I apologize. That being said, wouldn't the powertrain warranty cover it? Even after the powertrain warranty period/mileage is passed you can always request factory assistance and Ford will at least offer to cover some or most of the repair costs.

 

[ValenciaOrange]

I had the axels replaced on my truck. Good work. Zero cost. I don't think you would be qualified to work for Ford. You are to smart and logical.

 

[ValenciaOrange]

Having my CV axels replaced today. The dealership has had my Maverick the previous two days as well for recall work. They just texted me a moment ago they also want to replace my driver's side axel shaft because there still getting shaking while accelerating. This truck is starting to piss me off, lol.

Have them replace both sides. They did this for me.

 

[ValenciaOrange]

at 28K miles isn't this under warranty?

Yes it is

 

[nocebo]

Have them replace both sides. They did this for me.

Believe they did, plus they're replacing my driver side axle shaft now.

 

[23grayXLT84]

Alright, then start your own thread about it but right here right now in this thread the OP modified their vehicle beyond OEM spec which should not be submitted as a factory safety defect.

You do realize that forums (this and other platforms) are littered with axle failures. Now that many owners have some miles under their belt, issues come out.

It's a damn CV axles, not ground breaking technology.

 

[23grayXLT84]

I worked at a Chevrolet Dealer for 22 years. Aftermarket suspension lifts and lowering do in fact cause things to fail prematurely. Talk to an engineer if you don't understand this, but it's probably more like you don't want to understand this and just put the blame on Ford.

These are failing at an alarming rate on non modified trucks. Do some reading.

110% Ford is to blame here. It's a shit design, or shit quality (likely both).

 

[StevenC56]

These are failing at an alarming rate on non modified trucks. Do some reading.

110% Ford is to blame here. It's a shit design, or shit quality (likely both).

Again as I stated above, I apologize if there is a huge percentage of failures on non modified vehicles that show no signs of abuse or outside influences that contributed to the failures. Alarming failure rate? Any idea what the failure rate is? 5%? 50%? Are they not covering repairs under warranty? Are they denying requests for repair assistance after the powertrain warranty expires?

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