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Another broken Axle bolt

Ed21

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Thanks for the picture.
I'm always wondering why all these pics with broken or removed bolts show the axle NOT flush with the hub. It seems like as you torque the bolt it would draw the axle up against the washer and hub shoulder.
Or put another way, I have yet to see anything about the axle shaft itself that would stop it from coming outboard enough to seat against the bolt. So why are most of the pictures showing the axle inboard a few centimeters?

I guess it's possible that the axle wants to move inboard if the fastener/bolt isn't holding it from moving?
I keep coming up with the questions:
1) Is the axle supposed to be flush with the hub after assembly or does it work itself inboard over time. It's supposedly a press fit into the hub. If the axle can be moved in the hub easily and it's not flush with the hub that bolt is going to break every time from the microscopic flexing in the gap IMO.
2) Was the bolt tight in the axle upon backing it out for replacement? (I assume it was).
3) Is the washer at the inboard part of the spline bottomed out against the hub before bolts were backed out or at any time after assembly? It would be nice if somebody could examine this stuff if they get the opportunity. IMO even if the shaft is a press fit and not flush with the hub that gap poses a problem for that bolt.
 

Hfyvr

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Is it me or does this axle bolt seem way undersized for the application?

I’m pretty new to the powerboost and F150’s but I’ve been around the VW world for a long time and the axle bolt used on a Golf looks to be around 2-3x the size of that bolt. Something to think about is whether they’re actually applying the right torque specs. For the MK5 VW’s there were a total of 3 different axle bolts available for the same application. Hex head, 12 point with ribs on the mating surface and 12 point without ribs. Took anywhere from 70nm to 200nm plus a quarter or half turn. Huge variance in torque depending on what you received from the dealership and many got over torqued if you didn’t look up the right one.
 

FirstFord

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Well, it's my turn in the barrel. Just learned moments ago. 14,980 miles. I was really hoping that I was going to be one that skipped past this issue. 😡
 

Buyer2021

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Well, it's my turn in the barrel. Just learned moments ago. 14,980 miles. I was really hoping that I was going to be one that skipped past this issue. 😡
Bummer. :cry:

What's the build month on your door frame sticker, please?
 

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FirstFord

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What's the build month on your door frame sticker, please?
It was built Feb '22. Max Tow Package equipped.

Edit: I did not physically check the door pillar sticker, because it wasn't necessary. I custom ordered my truck, and followed the process closely. If I recall correctly, it was built between the 21st and 24th of February. I took delivery March 17. 🍀
 
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John861

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Finally.... A recall for this issue. I'm interested to see what they will replace.
 

AndreB

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