Axle Housing Broke

[Agent M79]

Pulled out of my white concrete driveway Friday and noticed a dark spot where the rear end sits. Thought it might just be a little left over oil from the new girdle I had installed.

Decided to park the car the other way around and observe. Did take long for a drip to appear about 8 to 10 inches from the differential on the axle housing.

What do I know about this stuff? Nothing.

Monday AM was the first chance I had to address it. By that point there may have been a pint of oil on the ground.

I limped it over to the local dealer.

They said the axle housing at the differential was leaking. Asked them how something like that happens. They said it had to be bad from the factory. This stuff just doesn't "happen" without there being very obvious damage.

This will be repaired under warranty. I'll keep you posted.

[Marauderman]

Pulled out of my white concrete driveway Friday and noticed a dark spot where the rear end sits. Thought it might just be a little left over oil from the new girdle I had installed.

Decided to park the car the other way around and observe. Did take long for a drip to appear about 8 to 10 inches from the differential on the axle housing.

What do I know about this stuff? Nothing.

Monday AM was the first chance I had to address it. By that point there may have been a pint of oil on the ground.

I limped it over to the local dealer.

They said the axle housing at the differential was leaking. Asked them how something like that happens. They said it had to be bad from the factory. This stuff just doesn't "happen" without there being very obvious damage.

This will be repaired under warranty. I'll keep you posted.

Oh NO!! Hope this won't keep you from this weekends meet---It may be bigger than we thought----....Keep us posted and stay tuned here for updates to this weekends meet---changes are in the works!!!

[Ross]

Scary. If this came from the factory like this, I wonder if they had a run of bad ones, and some of us might be in for the same trouble. How many miles on your car?

[Agent M79]

mman - They say that it will be ready by Wednesday evening. We'll see. Unfortunately, if I am not 100% sure the matter has been resolved, I likely won't make the haul to Fayetteville. Gotta play this one as it comes.

Ross - I don't know if it is a generic flaw or a one off. I don't know of any changes on this part from the '03 so I am suspecting that we'd heard of this already. I am just short of 6,500 miles.

My other problems have been minor but they are mounting. I love this car, but it's a real drag that I have something or other to deal with every month.

[gonzo50]

I limped it over to the local dealer.

They said the axle housing at the differential was leaking. Asked them how something like that happens. They said it had to be bad from the factory. This stuff just doesn't "happen" without there being very obvious damage.

This will be repaired under warranty.
:bigcry: "DAMN" are they going to install everything you already have on the car, ie...4.10 gears, TA performance girdle, stud kit....etc ?
Or do they have to put the originals back in, ie...3.55 gears, factory housing cover ? :confused:
Hope all turns out good for you Agent M79. :beatnik:

[TripleTransAm]

Wow, looks like the '04 really does have improved low end torque, to be twisting up axle housings like this. ;) ;) :lol: :up:

Hope it works out for you.

[Dr Caleb]

Dude! Sorry to hear this.

Just a question. . . to your knowledge, has the car ever been jacked up by the rear diff housing? Classic symptom if it has been . . . just FYI.

[BillyGman]

Hmmm, a very interesting point Caleb.

[Agent M79]

I have never jacked the car up and certainly would not from the housing.

All other visits are to dealerships.

I can recall no other situation where the back end would get jarred... no curb hopping, no low clearance hits. Nothing.

The backend was opened in Atlanta and once in Charlottle for... service... but I can't imagine that being a problem.

[RCSignals]

I have never jacked the car up and certainly would not from the housing.

All other visits are to dealerships.

I can recall no other situation where the back end would get jarred... no curb hopping, no low clearance hits. Nothing.

The backend was opened in Atlanta and once in Charlottle for... service... but I can't imagine that being a problem.

You say it "broke". what actually "broke"? Where is the leak from?

Yes, opening the differential and "servicing" the differential could be the cause of a leak.

Was the girdle installed properly?

[Agent M79]

RC, I am no mechanic but I will tell you what I can.

The dealer characterized it as a break in the axle housing where the axle housing joins the differential. It must have been a smallish "crack" more than a "break" because I was able to drive it the short distance to the dealer with no additional damage or strange sounds or anything.

The only thing about the girdle install that I am capable of telling you is that it was there and in the same position as the old one when I looked at it. All the bolts were there and it was clean and oil free.

[Ross]

This is really a long shot, since I know nothing about this. Here goes. When re-installing the cover on the rear end, is it possible to over torque the bolts and cause a crack? Maybe an over torque situation wouldn't crack the steel right away, but would stress it so that over time a crack would develop. OK, I've shown my ignorance, back to our regularly scheduled thread.

[BillyGman]

no Ross. The worse that can happen w/those small bolts that are used for the cover is that over torqing would cause the threaded holes in the housing to strip. that is that merely the threads in the holes would be stripped and they would have to be re-threaded or drilled over sized and re-threaded for bigger bolts.

But even doing that would NOT crack the housing since you're only talking about a required torque of 30 ft/lbs which isn't a tremendous amount of torque. So I'm sure that the bolt holes in the housing would strip out before you even reached 50/ft/lbs of torque and that isn't even nearly enough to crack the differential housing nor the axle tubes themselves. But hey, it's always okay to ask. :)

[RCSignals]

It has been said the axle tubes are pressed in place. That not done properly could set up for a leak later.
The other option would be as DR Caleb said, at some time the rear may have been jacked improperly. The car may also have been chained down improperly in transit to the dealer.

[SergntMac]

Ummm...How about the rear end twisting itself in six different directions under WOT...

[03SILVERSTREAK]

It has been said the axle tubes are pressed in place. That not done properly could set up for a leak later.
The other option would be as DR Caleb said, at some time the rear may have been jacked improperly. The car may also have been chained down improperly in transit to the dealer.Has anyone considered the possibility of Mig welding the axle tubes to the rear end housing to strengthen the entire rear end and to prevent any leaks. I have seen several posted pics in the gallery that members posted when they installed the Girdle and noticed what looks like a oil leak coming from where the axle tube joins the rear end unit...

[Agent M79]

It has been said the axle tubes are pressed in place. That not done properly could set up for a leak later.
The other option would be as DR Caleb said, at some time the rear may have been jacked improperly. The car may also have been chained down improperly in transit to the dealer.Hmmm... I did have the radiator hose episode 2 or 3 weeks back. It was flat bedded.

Could it have been damaged enough to have delayed the first leaks for that long?

[RCSignals]

Hmmm... I did have the radiator hose episode 2 or 3 weeks back. It was flat bedded.

Could it have been damaged enough to have delayed the first leaks for that long?

It's possible

[RCSignals]

Ummm...How about the rear end twisting itself in six different directions under WOT...


At some time people with that much problem at WOT might have to start looking to a custom 9" rear

[BillyGman]

Has anyone considered the possibility of Mig welding the axle tubes to the rear end housing to strengthen the entire rear end and to prevent any leaks. I have seen several posted pics in the gallery that members posted when they installed the Girdle and noticed what looks like a oil leak coming from where the axle tube joins the rear end unit...

I DO know that MIG welding creates a very durable seal. However, I think that the leaks that are experienced w/the use of these covers are due to the covers themselves. it's my guess that the leaks are actually coming from somewhere on the cover, or where it meets the housing, and the leaking fluid simply forms a trail at the lowest point and drips off of the axle tubes. So it can appear that it's coming from the axle tube even though it isn't.

I'm not saying that this is neccessarily the case w/M79's ride, but I do think that is likely the case w/the majority of guys who have had leakage problems w/these covers.

[CRUZTAKER]

Hmmm... I did have the radiator hose episode 2 or 3 weeks back. It was flat bedded.

Could it have been damaged enough to have delayed the first leaks for that long?Oh man, I've seen those guys use chains to pull vehicles up onto the bed, and secure the vehicle under tow as well.

Did they front or rear load the vehicle onto the flat bed?
And when the vehicle was on the bed, did they secure it with chains and a come-along looking device?

There should be marks on the axle if they did. :nono:

[Agent M79]

Oh man, I've seen those guys use chains to pull vehicles up onto the bed, and secure the vehicle under tow as well.

Did they front or rear load the vehicle onto the flat bed?
And when the vehicle was on the bed, did they secure it with chains and a come-along looking device?

There should be marks on the axle if they did. :nono:
It was pulled from the front. He was very careful (it appeared) because he saw the back end getting close to the ground and brought out some ramps to take some of the steepness off the angle of climb. One up there tho, I was in my rides car getting in position to lead him to the dealership.

[03SILVERSTREAK]

I DO know that MIG welding creates a very durable seal. However, I think that the leaks that are experienced w/the use of these covers are due to the covers themselves. it's my guess that the leaks are actually coming from somewhere on the cover, or where it meets the housing, and the leaking fluid simply forms a trail at the lowest point and drips off of the axle tubes. So it can appear that it's coming from the axle tube even though it isn't.

I'm not saying that this is neccessarily the case w/M79's ride, but I do think that is likely the case w/the majority of guys who have had leakage problems w/these covers.NO-Im talking not about the rear end girdle cover , but were the axle tubes are pressed into the rear end housing unit . Some one on this site stated that Ford in its mission to save a few dollars do not weld these axle tubes into the rear end unit . thats were some of the posted pics show in the background oil leaks coming from the tubes by were they are pressed into the unit , unless ford never welded them in the past...

[BillyGman]

I didn't think that they ever were welded in the past either, but I'm not positive about that though.

[FordNut]

I didn't think that they ever were welded in the past either, but I'm not positive about that though.
I believe they have been this way ever since the 8.8" rear end came out, about 1980 or so. The tubes are pressed into the center housing. There is a small hole in the center housing on each side which is spot welded to the tubes. At least that's the way it was on the MkVII rear end setting out in the garage. But they are not welded all the way around, which would be the best way to prevent leaks.

A killer custom 9" unit would be great for supercharged cars for drag racing, but the 9" is a lot heavier than the 8.8" so it may not be optimum for handling due to the higher unsprung weight. But a 9" ain't gonna break, that's for sure.

[03SILVERSTREAK]

I believe they have been this way ever since the 8.8" rear end came out, about 1980 or so. The tubes are pressed into the center housing. There is a small hole in the center housing on each side which is spot welded to the tubes. At least that's the way it was on the MkVII rear end setting out in the garage. But they are not welded all the way around, which would be the best way to prevent leaks.

A killer custom 9" unit would be great for supercharged cars for drag racing, but the 9" is a lot heavier than the 8.8" so it may not be optimum for handling due to the higher unsprung weight. But a 9" ain't gonna break, that's for sure.So again-to any and all the expert Ford wrenches out there , would this be a good idea or a bad one ???

[Agent M79]

Well. The parts didn't make it in today. Apparently this is a lengthy job, like 1/2 day or something.

[FordNut]

So again-to any and all the expert Ford wrenches out there , would this be a good idea or a bad one ???
I would not think it worth the hassle. I've been on MM.net for over a year and this is the first case I recall of a rear end housing having a problem.

[frdwrnch]

I agree w/Fordnut. I think it is a fluke or isolated failure. I've seen a couple of 8.8's leak in this manner in 5 years. If the car was drag raced regularly or consistantly launched hard then welding the tubes may be an ounce of prevention. This stud girdle and cover was installed with the rear end hanging while the vehicle was on a lift. While I am reaching here and don't want to cause unnecessary concern, it is remotely possible that the new girdle and cover were more rigid causing a new stress point at the tube joints. If this was the case it would have eventually leaked anyway after some miles were on the car. I like this mod and intend on doing it to mine soon. It's just weird that it happened three days after the cover installation.

[Agent M79]

...she's on the rack now... Hopefully she is ready to roll later today cause I sure would like to make to Raleigh this weekend!

[Agent M79]

Got it back! Drove it like I wanted it dead and she held her fluids and performed as I expected.

I'll be watching for spots on the driveway.

Thanks everyone for your input!

[frdwrnch]

Yeah! Glad you're on the road again. Looking forward to the road trip this weekend. I'm jealous, you've got a shiny new rear end housing and mine is already starting to surface rust. I figure I'll wire brush mine and either clear it or paint it black when I do my stud girdle.

[Fin Harder 92]

Dave, Glad to hear all is well. I look forward to seeing you this weekend.


Take Care