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

[StevenC56]

Well I had BOTH axels replaced at 11k miles on my totally Stock Hybrid Maverick Lariat. I am at 29600mi now and just bought extended warranty as expect to have them replaced probably twice more before I get to 100K.

You are the first person with an unmodified Maverick that's chimed in on this thread anyway. I'm sure there's more, but it may not be the huge numbers that a few people are saying. You live in Florida. I wonder if major rainfall or some other environmental factor might have some effect on the failures? I'm not saying that the cause, but perhaps the CV boots are allowing water to intrude.

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[gp1200x]

So I had a 2014 Escape with a 2.0 EB fwd that I put 75,000 miles on.
My wife has a 2019 with the same powertrain with almost 40,000 miles, both have been trouble free in regards to the cv joints and axels.
Do the Maverick Ecoboost models use a different cv joint than the Escape?
Could the leveling lift be contributing to the failure?
I think it shouldn’t but who knows.
Great write up!

Yes, different CVs

 

[gp1200x]

The service manager whom I'm actually pretty friendly with, thinks the clicking is normal or just part of the natural play in the steering rack. I'm wondering how I'm going to get him or his tech to see the real issue. Is there something I can point to and say "hey double check this"?

From my experience any "clicking" noise that you can hear all the way inside the vehicle from outside is usually metal against metal and that means wear and usually something that will not last very long. I have never had any clicking noise from my r&p systems. All my CV failures over the decades were preceded by clicking noises (usually more while turning or under torque stress) or noticeable vibrations under a load. They can sometimes fail quickly and go out completely so once you notice the issue look into repairs. Don't go on a trip!

 

[scottp01]

You are the first person with an unmodified Maverick that's chimed in on this thread anyway. I'm sure there's more, but it may not be the huge numbers that a few people are saying. You live in Florida. I wonder if major rainfall or some other environmental factor might have some effect on the failures? I'm not saying that the cause, but perhaps the CV boots are allowing water to intrude.

If anything being in Florida means they would be less prone to wear than someone in the rust belt having salt spray all around the drivetrain.

 

[acelee1895]

You are the first person with an unmodified Maverick that's chimed in on this thread anyway. I'm sure there's more, but it may not be the huge numbers that a few people are saying. You live in Florida. I wonder if major rainfall or some other environmental factor might have some effect on the failures? I'm not saying that the cause, but perhaps the CV boots are allowing water to intrude.

No lift on my hybrid, one size up on trail terrain tires from stock. Mine went out at about 35k. Replaced under warranty. At first they were gonna do both then they decided last minute to just do the passenger side. I've been watching this issue for a while and there have been more reports of modified vehicles with CV axles failing but if you go through the threads, there's plenty of reports of stock setups failing. I plan on buying one of the upgraded sets of those finally go

 

[colinl]

I am glad to see this post for the education/information it provides.

There is a straight on pic of the splines, and if I can paraphrase, it seems the OP wonders/theorizes if the design is weaker than full splines. Then a bit later @Bwicka shows the Tremor axles, but not a shot just like the one in the OP which shows the spline interface. It likely is the same - pretty much needs to be, if the Tremor axles can be used in place of standard ecoboost axles. But we don't see that.

Only other thing I noticed is that the OP commented on lifting the UCA to relieve the swaybar. Couldn't you just make the swaybar endlink removal step 1? If there's insufficient clearance to get under and do it before you jack up the front end, how about driving onto ramps?

 

[StevenC56]

Ford should cover the replacements under the powertrain warranty, and then extend goodwill repairs for a reasonable amount of time given the history of failures on stock vehicles.

 

[801Maverick801]

I am glad to see this post for the education/information it provides.

There is a straight on pic of the splines, and if I can paraphrase, it seems the OP wonders/theorizes if the design is weaker than full splines. Then a bit later @Bwicka shows the Tremor axles, but not a shot just like the one in the OP which shows the spline interface. It likely is the same - pretty much needs to be, if the Tremor axles can be used in place of standard ecoboost axles. But we don't see that.

Only other thing I noticed is that the OP commented on lifting the UCA to relieve the swaybar. Couldn't you just make the swaybar endlink removal step 1? If there's insufficient clearance to get under and do it before you jack up the front end, how about driving onto ramps?

You have to disconnect the Tie rod first to be able to turn the knuckle to be able to remove the sway bar bolt. The sway bar bolt does not have enough room with the wheel well to be removed in a perpendicular orientation of the truck.

 

[colinl]

Ford should cover the replacements under the powertrain warranty, and then extend goodwill repairs for a reasonable amount of time given the history of failures on stock vehicles.

a Ford dealership would if they were the ones to install the lift.

or they would cover it if the OP reverted to stock before bringing the truck in. but I am confident that if you have this issue on any Ford, and you take it in for diagnosis, they will immediately blame any non-stock suspension they see. that's just what they do, the same as your first post in this thread when you said you worked at a Chevy dealership and have seen this.

for most dealerships there's no shades of grey. modified suspension + CV issue = no warranty replacement is black and white to them. we can continue to debate whether that's reasonable or not, but I really don't care. the only exceptions I've ever seen are when a dealership installs the lift kit.

 

[StevenC56]

a Ford dealership would if they were the ones to install the lift.

or they would cover it if the OP reverted to stock before bringing the truck in. but I am confident that if you have this issue on any Ford, and you take it in for diagnosis, they will immediately blame any non-stock suspension they see. that's just what they do, the same as your first post in this thread when you said you worked at a Chevy dealership and have seen this.

for most dealerships there's no shades of grey. modified suspension + CV issue = no warranty replacement is black and white to them. we can continue to debate whether that's reasonable or not, but I really don't care. the only exceptions I've ever seen are when a dealership installs the lift kit.

Most dealerships won't do lifts and lowering unless the kit is from the manufacturer. Most any factory warranty also states failures due to modifications, abuse, lack of maintenance or outside influences are not covered. Depending on the dealership and your relationship with them there will certainly be grey areas of coverage or denial.

 

[AlsMaverick]

Ford should cover the replacements under the powertrain warranty, and then extend goodwill repairs for a reasonable amount of time given the history of failures on stock vehicles.

I don't necessarily disagree but what is the history? Can you quantify it?

 

[colinl]

Most dealerships won't do lifts and lowering unless the kit is from the manufacturer. Most any factory warranty also states failures due to modifications, abuse, lack of maintenance or outside influences are not covered. Depending on the dealership and your relationship with them there will certainly be grey areas of coverage or denial.

that must be your experience, sure.

but around my area, large dealerships routinely modify vehicles before they are sold, new or used. I mean, not every one, but they will sell you a brodozer silverado or a skateboard bronco, absolutely. probably a lifted maverick less often, but I'm sure they would do it and happily add their healthy markup and put it on the loan.

 

[StevenC56]

I don't necessarily disagree but what is the history? Can you quantify it?

All you'll really have would be the owners here on this large and popular Forum who could provide documentation to quantify the high failure rate unless you have a local club or multiple friends with the issue. Most manufacturers try to downplay issues like this until the can't any longer. If they don't step up, then here in California we have the Bureau of Automotive Repairs. And as a last ditch effort as some others have pointed out a Class Action Lawsuit.

 

[StevenC56]

that must be your experience, sure.

but around my area, large dealerships routinely modify vehicles before they are sold, new or used. I mean, not every one, but they will sell you a brodozer silverado or a skateboard bronco, absolutely. probably a lifted maverick less often, but I'm sure they would do it and happily add their healthy markup and put it on the loan.

True. Here in California the liability risk outweighs the profit potential for a dealer to modify vehicles in this manner.

 

[Guv]

a Ford dealership would if they were the ones to install the lift.

or they would cover it if the OP reverted to stock before bringing the truck in. but I am confident that if you have this issue on any Ford, and you take it in for diagnosis, they will immediately blame any non-stock suspension they see. that's just what they do, the same as your first post in this thread when you said you worked at a Chevy dealership and have seen this.

for most dealerships there's no shades of grey. modified suspension + CV issue = no warranty replacement is black and white to them. we can continue to debate whether that's reasonable or not, but I really don't care. the only exceptions I've ever seen are when a dealership installs the lift kit.

And even More Black and White given the shape of the economy.
Warranty work that years ago would have just been done requires an investigation, a lot of times communication with Ford and then hopefully, acceptance for the work to be covered by Ford.

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