Front drive shaft keeps failing with a 6” RC lift

[Yarik18]

So I’m gonna a be putting a 4th drive shaft. 3rd CV axle and 2nd front differential carrier (used, low mileage, 30k). I am at, About 61k and I’ve went through 2 updates on the rough country 6” lift kit. Now I have to applaud rough country, they helped every single time sending me free parts to fix the issue. I kept hearing people keep busting their driveshaft and driver side upper diff drop bracket. Last update was whole new drop racks and new brackets that changed the diff angle. That was a pain but they gave me everything to get it done. Now the top bracket was updated with thicker steel, much more beefier, second update. Well one of the times I took it off road and I don’t really do too extreme off roading, all on trail. The most recent bracket didn’t break but got warped. You can see that the welds are not at all acceptable. So I had my neighbor triple the welding to that bracket as it should have come. I have pictures for everything I’m talking about. After the last trip of me fixing it, couple blocks away from my house the clunking appeared and got worse and worse. Jacked one wheel up and spun it, the yoke of the axle showed movement. Nothing else and it all felt like the side with a problem was on the drivers side. Diff left side axle felt some uneven motion characteristics, like needle bearings were acting up in the diff carrier. So I replaced that, one mile down the road I start hearing ticking, then clunking, then thud, thud. So I attached a go pro to take a shot from both sides of the drive shaft. One side of me telling me it’s a bad diff carrier, one says bad transfer case, other most rational says the drive shaft is binding. With years of building off road rigs I was certain that it is a drive shaft. So I mounted the camera and as I it was recording the drive shaft broke. Now this is a an off brand drive shaft but new with waranty. I’ve replaced the drive shaft before but I’ve replaced them with a used one. Even with brackets breaking the oE held up more then this drive shaft. But again now I have the biggest wheels I’ve ever seen on a Ranger. I’m thinking the last time I was working on the diff drop bracket fix issue. In between that new axle got damaged.

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[diesel924]

So what're you going to do?

 

[got3fords]

Let's see pics of your shaft ruiner (your Ranger.)

 

[Fordup]

There's engineering limitations to everything. Surpass them and you have a money pit.

 

[OFC Ranger]

OP already knows the answer to the problem. OP just doesn't want to get rid of his 6" lift.

Or am I missing something?

 

[Dereku]

I dont mean to sound callous, but with all your years off roading why go RC and why go 6inches? The only IFS truck that has good lift support, without track widening, is Chevy/GMC.

RC was my first lift kit as a teenager, and last time I used them. Shocks are ass, springs are subpar, and all brackets looked poorly made. A 6in lift on our ranger is for show, not go. Unless you run extended control arms and custom CV shafts, you will never have a solid experience.

Just my 2c from 25 years of off the beaten path experience. And dozens of lift kits made/installed by me.

 

[Grumpaw]

My Ranger is a 2 wheel drive, and I have no experience with a lifted truck, but....
Ford Ranger is a light duty rated truck, and it was never designed for a 6 inch lift, which is probably putting an enormous strain on the drive components, the trans (which I wonder why it hasn't gone out on you). Additionally, the tires/rims your running has got to put additional strain on the system....probably one of the tires/rims weighs twice what one of mine do...
Rangers were never designed for the loading your placing on the stock arms, joints, suspension.
Bet if you went back to a 2-3 inch lift and some smaller/lighter tire/rim combos, your problems would go away.....

 

[Grandaccess]

you get your ground clearance from the tire, and lift is to clear the tires, the same stump that stops you will stop me and my 3 1/2, there are other reasons that 3 1/2 is a sweet spot for most trucks, center of gravity and handling
sitting on a telephone book will give you the same feeling?
I got 40k on a rough country 3 1/2 trouble free and no rub with 285/75/17 still handles good
I did replace the passengers tie rod at 35k but that could have been shitty NY roads too LOL
I had to spend the week in a Nisan rent a car this week LOL that sucked, you feel like you will slide your ass on the pavement at any time, I liked the 47MPG but that is it!, small ass mirrors, radio sucked, so low it was hard to get TF out of!

 

[5thranger]

So I’m gonna a be putting a 4th drive shaft. 3rd CV axle and 2nd front differential carrier (used, low mileage, 30k). I am at, About 61k and I’ve went through 2 updates on the rough country 6” lift kit. Now I have to applaud rough country, they helped every single time sending me free parts to fix the issue. I kept hearing people keep busting their driveshaft and driver side upper diff drop bracket. Last update was whole new drop racks and new brackets that changed the diff angle. That was a pain but they gave me everything to get it done. Now the top bracket was updated with thicker steel, much more beefier, second update. Well one of the times I took it off road and I don’t really do too extreme off roading, all on trail. The most recent bracket didn’t break but got warped. You can see that the welds are not at all acceptable. So I had my neighbor triple the welding to that bracket as it should have come. I have pictures for everything I’m talking about. After the last trip of me fixing it, couple blocks away from my house the clunking appeared and got worse and worse. Jacked one wheel up and spun it, the yoke of the axle showed movement. Nothing else and it all felt like the side with a problem was on the drivers side. Diff left side axle felt some uneven motion characteristics, like needle bearings were acting up in the diff carrier. So I replaced that, one mile down the road I start hearing ticking, then clunking, then thud, thud. So I attached a go pro to take a shot from both sides of the drive shaft. One side of me telling me it’s a bad diff carrier, one says bad transfer case, other most rational says the drive shaft is binding. With years of building off road rigs I was certain that it is a drive shaft. So I mounted the camera and as I it was recording the drive shaft broke. Now this is a an off brand drive shaft but new with waranty. I’ve replaced the drive shaft before but I’ve replaced them with a used one. Even with brackets breaking the oE held up more then this drive shaft. But again now I have the biggest wheels I’ve ever seen on a Ranger. I’m thinking the last time I was working on the diff drop bracket fix issue. In between that new axle got damaged.

I immediately went out to garage to show these photos to my ranger. I told the little diva if it starts giving me problems it has this carnage to look forward to. Of course, I had to wake it up because it just sits in garage sleeping.

 

[got3fords]

you get your ground clearance from the tire, and lift is to clear the tires, the same stump that stops you will stop me and my 3 1/2, there are other reasons that 3 1/2 is a sweet spot for most trucks, center of gravity and handling
sitting on a telephone book will give you the same feeling?
I got 40k on a rough country 3 1/2 trouble free and no rub with 285/75/17 still handles good
I did replace the passengers tie rod at 35k but that could have been shitty NY roads too LOL
I had to spend the week in a Nisan rent a car this week LOL that sucked, you feel like you will slide your ass on the pavement at any time, I liked the 47MPG but that is it!, small ass mirrors, radio sucked, so low it was hard to get TF out of!

Carolina squat?

 

[Dereku]

Carolina squat?

Thats a baby squat. Be nice.

 

[Dereku]

I have shared this before. I have done stupid in the past. But the vehicle has to be made for it. 1 ton drivetrain helps. And being longer, so the driveshaft isnt on a 45 degree angle.

 

[Msfitoy]

And women complain about wearing 6" heels...

 

[Dereku]

And women complain about wearing 6" heels...

Men would never complain about a 6” height advantage.

 

[Stevedbvik1]

Sounds like a high angle joint driveshaft needs to be engineered for your application. Probably will require different drive flanges at the tcase and diff. Don’t think the Rzeppa joint is meant to handle the angles you’re encountering.

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