Axle Shaft Problems of Ford Excursion

This is a 2000 Ford Excursion limited 4x4, v-10. The truck has 38,000 miles and is well maintained. There were no signs of leaking prior to failure. The only symptoms was a "knock" intermittently several thousand miles prior to failure, but no cause for the sound could be found on inspection. At the time of failure, the u-joint at the end of the axle shaft had 1/4" free play in it in all directions and came within 1/4" of hitting the bolt/nut assembly just below it. That nut holds the lower portion of the wheel spindle bracket in place. This is a potentially dangerous situation because if the bolt was hit by the u-joint with enough force, it could shear off causing the wheel to come off of the vehicle and lead to a crash. The vehicle is at the dealership for repair. However, since the actual failure happened after the 36,000 mile mark neither the dealer nor Ford will pay for any part of the repair. Both Ford and the dealer service department, do not know why the bearing failed. Nor do they know of any preventive measures. The vehicle has not been off roading beyond dirt roads and is running stock sized tires.

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