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FAD Delete

hightide

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With the catastrophic failures is it breaking the tube or is the tube pulling out of the FAD? If it's pulling out, welding around it might be a solution like what is commonly done on the ford 8.8 to keep it's tubes from spinning
 

foo.c

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The problem with welding on an axle tube is it is tricky to keep it square.
 

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rharr

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With the catastrophic failures is it breaking the tube or is the tube pulling out of the FAD? If it's pulling out, welding around it might be a solution like what is commonly done on the ford 8.8 to keep it's tubes from spinning
It's the FAD casting, it's the weak link in the assembly. It's about 1/4" thick and has bolt holes though it to further weaken it. I would bet, if you looked at the broken parts from the example above the crack would run through a bolt hole.

My friend had a snapped D44 HD ruby front axle at the shop from a glad that hit a concrete divider on the passenger side at 65 mph. The axle tubes, dif housing and ball joint mounts were all fine. The FAD cracked in half along a bolt line and the axle shaft mating ends at the FAD were marred up from rapid separation. Even the aluminum knuckle didn't look to bad and had a 50/50 shot of being fine.

IMO the FAD housing is the weak part, maybe a truss over FAD or the FAD internal assembly being removed and a 3/8" metal plate bolted over the FAD opening may added strength.

I may try to screw with the busted axle and cut the housing off and make a 10 mm thick steel sleeve to rejoin the 2 tubes together.
 

rharr

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yes, lots of FAD housings crack when pushed hard. Plenty of youtube videos.
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