Today I was driving down the freeway and all of a sudden I heard a clunk and a grinding noise. Let off the accelerator and when I pushed the accelerator again no power to the wheels, just a grinding noise. Great, I’m 400 miles from home and I know what that sound is, broken axel bolt again. The last one happened at 50,000 miles, now at 120,000 miles it did it again. Got it towed to a dealer, the service person told me Ford has a recall, (which I already knew) she said Ford has not figured out a permanent fix yet all we can do is put a new bolt in it, does anyone know if this is true or not? 400 miles from home, out $150.00 for hotel room because of a very poor design. Hopefully they can get it fixed tomorrow.
Second time my axle bolt has broken
Mokehill
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Today I was driving down the freeway and all of a sudden I heard a clunk and a grinding noise. Let off the accelerator and when I pushed the accelerator again no power to the wheels, just a grinding noise. Great, I’m 400 miles from home and I know what that sound is, broken axel bolt again. The last one happened at 50,000 miles, now at 120,000 miles it did it again. Got it towed to a dealer, the service person told me Ford has a recall, (which I already knew) she said Ford has not figured out a permanent fix yet all we can do is put a new bolt in it, does anyone know if this is true or not? 400 miles from home, out $150.00 for hotel room because of a very poor design. Hopefully they can get it fixed tomorrow.
New bolt?
That wouldn't get you back on the road. Especially if the axle splines had already fretted enough to inhibit driving force to the hub.
I sheared a bolt and the truck was 100% drivable. But Ford still replaced both axles and hubs. As soon as I got home I removed the factory bolts and replaced them with "better" bolts at considerably less torque than the service manual calls for, as well as added a Bellville washer.
Now when I rotate my tires I change the two bolts out and check for the splines to be still press fit. (no fretting)
So far so good. But admittedly I'm less mileage than you.
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That wouldn't get you back on the road. Especially if the axle splines had already fretted enough to inhibit driving force to the hub.
I sheared a bolt and the truck was 100% drivable. But Ford still replaced both axles and hubs. As soon as I got home I removed the factory bolts and replaced them with "better" bolts at considerably less torque than the service manual calls for, as well as added a Bellville washer.
Now when I rotate my tires I change the two bolts out and check for the splines to be still press fit. (no fretting)
So far so good. But admittedly I'm less mileage than you.
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It’s only on the 3/4 Float 9.75” HD axle that came on the 2021+ powerboost, hdpp and max tow trucksThey must have come up with a new design. Never seen a REAR axle bolt there. I can’t picture in my small brain what that is securing.
That bolt literally is there to "hold" the floating axle at its most outbound position.They must have come up with a new design. Never seen a REAR axle bolt there. I can’t picture in my small brain what that is securing.
Or put another way, the axle has splines on both ends and nothing to determine where exactly it should stay. Since it IS press fit into the hub, it's the hub end that is holding it from sliding further into the differential. That bolt just insures the axle can't move further into the differential if the press fit friction isn't sufficient enough to do the same.
Fellas can shear that bolt and be unaware. Nothing falls off or comes apart.
Look closely at red circle. You can see the splined mating of axle and hub. The bolt threads into the center of the axle and tugs on the axle to keep it from sliding further into the differential. (it can move inward about 1" without the bolt. Reducing the spline surface by 1" leads to fretting and eventually shearing the splines)
After speaking with the service adviser, she said that the bolt did not break this time. The axel broke and the spline is stripped. They refuse to replace both sides at this time. I did speak with Ford on the 800# and she said I was lucky I had extended warranty because Ford still doesn't have a fix yet and I get a free rental car. (She was nice) I think it's time I cut my losses and try a different manufacturer
Gone 2014 Ruby red FX4 with boost short box, Screw. New 2025 Lariat 7.2kw powerboost
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1,181 Posts
What causes the bolt to break? Is I backing out and allowing the hub to wobble on the axle or is there a minute amount of wobble even if tight? Both could flex the bolt enough to work harden it become brittle and break especially in the head/ shaft area where I have seen most of the breaks happen
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131 Posts
There is ""wobble" in the bolt when tight....
Ford's description is "The combination of vertical and lateral load upon the wheel-end creates bending fatigue of a specific wheel fastener, which can lead the bolt to break."
The bolt is garbage, in my opinion.
And I also think the torque spec is beyond what a 12x1.75 grade 8 bolt should be.
Again, just my opinion.
Like I said earlier, I replaced mine with an aftermarket bolt torqued at 84ftlbs. Added the Bellville washer for some "give", if you know what I mean.
It's le$$ than $10
No way am I letting go of the most amazing 1/2 ton truck I have ever owned because of the shortcomings of Ford to address the fix.
10 new axles wouldn't cover the co$t of depreciation, just to make a point that Ford would never even feel.
And I also think the torque spec is beyond what a 12x1.75 grade 8 bolt should be.
Again, just my opinion.
Like I said earlier, I replaced mine with an aftermarket bolt torqued at 84ftlbs. Added the Bellville washer for some "give", if you know what I mean.
It's le$$ than $10
No way am I letting go of the most amazing 1/2 ton truck I have ever owned because of the shortcomings of Ford to address the fix.
10 new axles wouldn't cover the co$t of depreciation, just to make a point that Ford would never even feel.
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1,697 Posts
Standard torque for a metric grade 10.9 M12 x 1.75 is 88ft/lbs. Not sure what Ford's torque spec is.
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131 Posts
I believe the spec for this bolt from Ford is 52 lb-ft and then add a 90 degree turn which puts the bolt into material yield condition.
Cummins lost me with hydraulic lifters in 6.7 Diesel turned a dead reliable motor into a 💩
Why wouldn’t Ford just done a regular full float like a Dana 70 multiple bolts on the axle end.
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131 Posts
Probably because $$$. They had a Max Tow/heavy payload option for their F-150's prior to 2021, I had two of them, and they never had any issues. Changing the design likely saved them a few dollars per truck. Now it is probably going to cost them a LOT more than a few dollars to correct it, not to mention the number of axles they've already had to replace.
Gone 2014 Ruby red FX4 with boost short box, Screw. New 2025 Lariat 7.2kw powerboost
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1,181 Posts
Are the ‘25 s max tow equipped with the same axle?
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131 Posts
I saw on another forum a design change in 2024 but when I looked it up on parts.ford.com, I came up with the same axle assembly.
It's really a very simple design. At least the axle itself. It's a mystery to me what could be the reason for the unexpected design failure.
And although the failure rate seems to have significantly diminished, compared to a couple of years back, nobody knows or can exhibit any differences between the components in the axles that don't shear that bolt and those that do.
I torqued a bolt with the Ford spec. (52ftlbs and then another 90°) I don't remember exactly what my torture wrench measured that to be but I do remember it FELT wrong. It was certainly more than ~84ftlbs.
And although the failure rate seems to have significantly diminished, compared to a couple of years back, nobody knows or can exhibit any differences between the components in the axles that don't shear that bolt and those that do.
I torqued a bolt with the Ford spec. (52ftlbs and then another 90°) I don't remember exactly what my torture wrench measured that to be but I do remember it FELT wrong. It was certainly more than ~84ftlbs.
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13,625 Posts
I've looked around a bit on this - and as @snakebitten says nobody knows...
But I found this tidbit elsewhere, posted in 2022, interesting on what Ford changed -
its all the max tow axles from what ive seen- they went back to a 1939 design "3/4 f;loat" axle, but splined it rather than taper fitted, the splines walking in its thou or two clearance, bolt gets stressed and breaks...
Anyone interested in reading the recall 23V896 - go here - (1) Recall 23v896 Rear axle bolts may break - certain 2021-2023 F150's. | F150 Ecoboost Forum1 - 20 of 42 Posts
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