Front axle control arm replacement

[bcbender]

I replaced my front axle in 2017' with a junkyard one after some beach bimbo hit me on the RF wheel and broke the rime / bent the axle ear (texting go figure)., I just used the best 4 link arms between the originals and the donor (OEM parts) I had (one was stuck on the axle and wouldn't come off) but I never had any issues with it or after. Must be some bad bolts or parts.

 

[MichaelOverfield]

[QUOTE="bcbender, ... Must be some bad bolts or parts.[/QUOTE]
Yes, it is. The lower control arms have insufficient size and hardness in the bushings, and it crushes well before the require torque can be applied. The "fix" I did got me to 150 ft-lbs.. but it appears that is not enough. I used all new correct bolts (OEM cam bolts). It's not the bolts.... its that lower control arm.. they should not be selling these, it's a safety issue.

 

[MichaelOverfield]

If you are getting a metal on metal clunk on compression check the upper control arm bolt on the driver side axle, if it was installed from the outside pointing toward the frame the end of the bolt can hit the frame.

Thanks, It's not the bolts, they are in the same as original per spec.

 

[Ozymandias]

Yes, it is. The lower control arms have insufficient size and hardness in the bushings, and it crushes well before the require torque can be applied. The "fix" I did got me to 150 ft-lbs.. but it appears that is not enough. I used all new correct bolts (OEM cam bolts). It's not the bolts.... its that lower control arm.. they should not be selling these, it's a safety issue.

150 ist plenty but not with a Bushing that collapses under that torque.

 

[bcbender]

Well if it collapses at that tq.. then its no longer 150, hence the safety issue with loosening fasteners.

 

[Ozymandias]

Nailed it!

 

[MichaelOverfield]

Ok FOUND THE CLUNK source.. front PML differential cover hitting the track bar mount on the frame.. It actually sheared off one bolt. Also, I was able to adjust the cam bolts back to marks, and then apply a full 200 ft-lbs, and it seems to have held. Time will tell if that holds the adjustment, the one side the seemed to have moved is coincidentally the side with the sheared differential cover fastener. Also I installed SumoSprings bump stops that are longer, which should help. My "fix" to the interference was to spot face the PML cover to recess the bolt heads, and use hex bolt vice the internal hex cap screws.. and I groomed the frame support to ensure no more contact. A rough ride over several speed bumps and rough roads seems to have verified the fix was effective. Pictures to follow:

 

[Ozymandias]

Could have told you so! It didn't work on mine either. Have thrown it into the trash.
Maybe usable for someone with at least 5 inch lift.

Did you really put a track bar drop bracket in for a 2" lift?
Why, that is absolutely not needed in any way, now you need to install a dropped pitman Arm to to restore steering geometry.

 

[MichaelOverfield]

Could have told you so! It didn't work on mine either. Have thrown it into the trash.
Maybe usable for someone with at least 5 inch lift.

Did you really put a track bar drop bracket in for a 2" lift?
Why, that is absolutely not needed in any way, now you need to install a dropped pitman Arm to to restore steering geometry.

No, there is no track bar drop. The 2inch was needed to get the 35inch tires to fit that I just installed, and the longer control arms it turns out were needed, as they keep the tires centered, where they would otherwise not fit.

 

[MichaelOverfield]

The PML cover works fine now by just spot face on those 2 capscrews now hex head an recessed, and my minor work to trim part of the bracket. Before the longer control arms, it had sufficient clearance.