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2009 F350 driver side knuckle sheared off #1026076 04/05/11 12:40 PM
Joined: Jan 2005
Posts: 1,528
barak Offline OP
Body Damage is Cool
Hi guys , I have a 2009 F350 6.4 Diesel that I drive for work.It is a King Ranch with 143,558 KM on it , and on Friday April 1 , I got stuck due to front end failure.

I work in the oil patch , and was doing a site in Alberta , driving through about 2" of mud due to the sudden melt of the big snowfall we had , resulting in the usual soft muddy roads this time of year.I was in 4 high , going slow , just enough to keep momentum so I didn't get stuck , and slow enough so the wheels were not spinning.I have been in much worse and never had a problem.Anyway , I was almost out after a few miles , had about half a mile of mud to go through , and I hear a bang and the drivers side front end dropped suddenly and that was it I wasn't moving.

I got out and looked at the front end , the fender was sitting on the tire , but the passenger side looked fine.With the mud I could not get a good look , but what I could see the ball joints where there but not attached to the tire, and the diff was hanging on the ground.There was no way a 2 wheel drive tow truck was going to get to me , so I had a tractor pull me to the road , and was taken to the ford dealer.

My boss stopped there yesterday to see how they were making out , and he was told the knuckle was sheared off , the half shaft was toast , and possibly the gears in the diff.They basically told him that I had run the diff dry.Now , for one , we baby these trucks , I just had all the fluids in the truck changed about 20,000 KM ago , and the diffs , transfer case and tranny get the fluids checked every oil change.Number 2 , if this was a case of no oil , wouldn't the diff seize up resulting in the diff basically grenading , probably snap the axle , and also toast the transfer case, not just do damage to one side of the truck?Also , how would the oil come out all the sudden unless the diff was compromised or the plug?

I am thinking I am lucky this happened while going slow , and not while doing highway speed because the truck would have rolled big time.I have never seen this kind of damage to a 4x when I wasn't working it hard at all.Normally you see tie rods , universal joints , ball joints , or if you work it really hard , a control arm.

Has anyone ever encountered this at all or something similar?I am thinking there was something weak on the truck , and it let go , and this is not the first major problem on this truck , so the boss is getting rid of it and putting me in a 2011.


1996 Jeep Grand Cherokee 5.2 with mods.Hughes Air gap intake , 52MM TB , ford injectors, 2 3/4" lift, Doug Thorley headers , HID headlights with LED , HID fog lights , glow gauges , a few others
Re: 2009 F350 driver side knuckle sheared off [Re: barak] #1026077 04/06/11 06:21 AM
Joined: Feb 2000
Posts: 6,247
4x4Wire Offline
Trail Leader
***
I agree with your observation. A dry diff would have resulted in bearing failure and problems before a sheared knuckle.

IF the diff were dry, it would mean there was a seal failure or someone pulled the drain plug. I don't know specifics with that axle; however, most diff plugs are screw in...

A failure of the diff where it seized may or may not reflect back to the transfer case. Remember, if something does seize, the weak link will break.

I would think the weak link would be a u-joint before the T-case.

Sheared knuckle??? Not sure that would be a stress point.

I do know that when going through mud, steering is an issue and I have blown a power steering pump. That is cheaper than axle carnage.


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