Driveshaft problems of the 2000 Ford Econoline

Front weld at universal joint, failed causing driveshaft to drop to the ground while driving at approximately 35 mph. Examination of the failed components suggests a likely fatigue failure caused by a poor weld. Weld contained sphere-shaped pores and was not centered on the interface between the u-joint and the shaft. Although failure was likely caused by a manufacturing defect, dealer has thus far denied a warranty claim citing to the vehicle's mileage. Since this weld was probably produced by automated equipment, it is conceivable that other driveshafts manufactured during the same time period may also be defective. A failure at a higher speed, such as on the highway, may result in much more serious consequences.