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You just might be right. After changing the driver side the only thing I observed was that the 2 bolts seemed over torqued. I had no backlash in the splines, the CV joint moved axially eliminating axial load on the bolts, I had hard washers showing no bending that would tend to cause a high...

Gulf GT, Right on!

nota4re, I searched the internet far and wide for many different bolts. I ordered half a dozen different types of bolts to choose the best one. I could have ordered a custom one but I'm too impatient to wait so long. My take is the strongest bolts are about 12.9 or grade 8, 170ksi to 200ksi...

I have replaced the driver side bolts yesterday. 1) I have a 2006 #89 build date Nov 2005 2) Bolts were real tight and loctited with hard washer. 3) The bottom of the heads showed signs of being real tight, a little too tight I think. 4) I had absolutely no backlash between the axle and hub...

Prowler, sorry to hear you had two axle failures! Could you please tell me if you had broken bolts or were they loose and fell out? If the bolts broke, did they break at the head? If the heads broke off could you send them to me and I will be happy to have an analysis done to determine if...

Jay, is there any chance of getting some details on your solution? I am a mechanical engineer, 25 years. I've attached many things to many other things that breaking or falling off is just plain old not an option. I've designed many things that are attached to satilites, helicopters, F16's...

John Mihovetz, Do you have any idea what kind of axial loading the hub would see in a worse case sceanrio? I was told by Ford the CV joint near the tranny slides axially and therefore I would assume there is no large axial loads. I am thinking of adding a needle thrust bearing to allow the...

Hello Kendal, Good write-up. I agree with all you say. It is important to note that with bowed washers an extremely high load on one side of the bolts happens, this is probably a large contributor to the heads snapping off. The stronger washer should help prevent this. I have already found...

Mine is "crunching" from 1-2 and sometimes into 1. #89 Tungsen Nov 5 build date. Sometimes even just plain hard to get into first gear especially when cold. Temps here are 30's these days but also noticed in Aug and Sep too but not as bad. It gets better after well warmed. I'm also getting...

Hi Dave or DBK. I have to disagree that if the shaft comes loose it is not a saftey issue. It is an extreme saftey issue for sure. As I was pulling out into traffic this morning I was really hoping my axle did not break so that the giant truck coming at me would not slam into me if I got...

Another note on torque of the two screws. TSB 05-10-13 states torquing to 40Nm. TSB 06-23-8 states torquing to 20Nm then to 30Nm. Seems Ford took over-torquing as an issue so lowered it in the 2nd TSB. I am starting to believe that the backlash slop in the axle splines and hub could help snap...

For what it is worth the Ford dealer said that the TSB specs are probably the specs to follow instead of the manuals since there are usually different specs and call-outs. This makes sense to me since I hope the engineers creating the TSB's spend a bit more time thinking about what to do. The...

In TSB 06-23-08 it mentions to torque the two bolts to 30NM. Turns out 30NM torque is the standard torque value for a metric grade class 8.8 This tells me the standard bolts used by Ford are standard steel not Class 10.9 or Class 12.9 which are much stronger bolts. It is possible Ford is...

Bolt picture Here is a photo of an example of the type of bolt I am looking for. I had to delete my other photos of the gaps to make room for this photo. Another pain....

sample bolt Hi AMB, I have seen the size of the bolts to be 25mm, 30mm and now from you are saying 25.4mm long. Did you measure one? When I get the kit it will be the first thing I do. Turns out 25.4mm is exactly 1 inch, I've never seen a metric length of 25.4mm. I'd be happy to pay $10 a...

Hi Jay, thanks for your info. I am certainly interested in your analysis. I am also hoping, once I take things apart to also understand how the whole thing works. I am assuming myself that the failures so far are due to either loosening bolts or the heads break off. I don't like the bowing...

OK, I went to a local large Ford dealer to order the thrust washer upgraded replacement kit. Turns out the p/n is 4G7Z-7B368-BA. The BA means the upgrade to better washer. I am not sure if the bolts are better. I get the kit next week. I am still looking for the best replacement screws. I...

I rigged up a video camera pointing at the wider gap side (passenger side) and went for a spin. Basically I saw no movement of the hub, the gap did not get any larger or smaller. If the two bolts were loose I would expect some movement. Since some other owners also have odd gap sizes this is...

Thanks for the comments. I am going to hook up a small video camera looking directly at the hub and go for a spin to see if there is movement of the hub during driving. I'll post my results. Seems there should be axial movement of the hub during driving.

Does anyone else seem to have the same problem with having the gap sizes so different? If it weren't for the axle problems I probably wouldn't think anything of it. This large gap makes me feel like that side is loose and ready to break. Only 850 miles on a 2006 Tungsten. Driven fairly...