Both Leaf Springs Broke

[woodworker]

I took these pictures

here are some pictures of mine still on the truck. They look identical to these. I am still waiting to hear from the dealership tomorrow see if they will replace them.

I’m certainly not a metallurgist by any stretch but I’ve been around more machinery in 60+ years than I care to remember and have seen failures that were easy to explain and some that were not. Anything from lawn mower engines to Naval ship propulsion equipment to 2400 megawatt nuclear reactors. Some that were latent failures due to the manufacturing process and some that were just due to improper maintenance or failure due to use other than intended. I’m calling this latent failure in the manufacturing process in that the end eyes were not properly tempered while being curled. Too many breaking in the same spot and it’s pretty rotten service that Ford will not acknowledge a problem like this. Sad indeed.
My friends brother in law had the Tacoma rotten frame issue and as much as I despise a Toyota (that’s another story), they took that truck back, completely stripped everything off the old rotten frame, bolted everything on to the new “better” frame, and gave it back at no cost to him except for some additional upgrades he wanted they had it torn down. Can’t even imagine what that cost was to Toyota. Maybe Ford should take some lessons from them.
I‘m at 151,000 on my 2021 and am very concerned after seeing all of these posts.

Sponsored

 

[Trustable]

I’m certainly not a metallurgist by any stretch but I’ve been around more machinery in 60+ years than I care to remember and have seen failures that were easy to explain and some that were not. Anything from lawn mower engines to Naval ship propulsion equipment to 2400 megawatt nuclear reactors. Some that were latent failures due to the manufacturing process and some that were just due to improper maintenance or failure due to use other than intended. I’m calling this latent failure in the manufacturing process in that the end eyes were not properly tempered while being curled. Too many breaking in the same spot and it’s pretty rotten service that Ford will not acknowledge a problem like this. Sad indeed.
My friends brother in law had the Tacoma rotten frame issue and as much as I despise a Toyota (that’s another story), they took that truck back, completely stripped everything off the old rotten frame, bolted everything on to the new “better” frame, and gave it back at no cost to him except for some additional upgrades he wanted they had it torn down. Can’t even imagine what that cost was to Toyota. Maybe Ford should take some lessons from them.
I‘m at 151,000 on my 2021 and am very concerned after seeing all of these posts.

I would think for as much as you drive if it could happen to you it would have already. Might not be a bad idea to just plan for it just in case though. I remember there was a thread in here of somebody putting in a multi leaf pack so that’s another option.

 

[Jason B]

I haven't gone looking but I wonder if the 6G has monoleafs still. If not it would suggest Ford realized the leafs they put on the US 5G was a mistake and I'd think a costly recall to swap to multileafs (like the UK ones I got off eBay) should be imposed on them - or financial compensation. Otherwise everyone gets 5G Tremor leaf packs.

6G FX4 here, same set up on 24+. Single leaf spring, plus the helper as on 5G.

 

[Titchadesh]

Had the same break point on the driver’s side towards the end of last summer. Would never had known until it was up on the lift for another issue and the mechanic notified me.

Took the opportunity to swap to the Icon leafs and have never looked back

 

[woodworker]

I would think for as much as you drive if it could happen to you it would have already. Might not be a bad idea to just plan for it just in case though. I remember there was a thread in here of somebody putting in a multi leaf pack so that’s another option.

Agree

 

[Texasota]

I had the same failure on the driver's side. Being a long time Ford customer with numerous vehicle purchases, Ford paid for the parts and I paid for the labor. Still cost me a tad over $500, but that has been my only repair expense on my 2020 XLT. I was okay with it.

 

[Racket]

6G FX4 here, same set up on 24+. Single leaf spring, plus the helper as on 5G.

I hope Ford fixed the issue by now- if it only showed up in certain build dates maybe a manufacturer fudged the spring manufacturing like the roof trim, air conditioner vent box and shifter boot. If it's common across all of the 5G production then I wonder how soon this will start popping up in the new generation forum's topics.

 

[rpeterson53]

I hope Ford fixed the issue by now- if it only showed up in certain build dates maybe a manufacturer fudged the spring manufacturing like the roof trim, air conditioner vent box and shifter boot. If it's common across all of the 5G production then I wonder how soon this will start popping up in the new generation forum's topics.

Just found the forward attach point on the right rear leaf spring fractured on my 2019 Lariat with 62,000 miles. By the appearance, it appears to have been broken for some time. Noted an unusual noise and investigated. I don't live in the rust belt and the undercarriage and components are rust free.

I have the Ford ESP warranty. Called the dealer and they could not tell me if this was under warranty. Its a 25 minute drive to the dealer plus need to inconvenience someone to pick me up after drop of. If under warranty, I would expect they would only fix the right side and not the left. I'm sure there would be an upsell to replace the left side at my cost.

I've looked at the Icon spring aftermarket as an option. I could have a local repair shop do the install or myself. I have all the tools and equipment plus a 16 year old grandson that wants to learn and help his 77 year old grandpa.

Anybody have experience with how Ford deals with a fractured leaf spring under the Ford ESPO warranty ?

Cheers

 

[Racket]

With the proper shop tools it's not super complicated to do and the chance to work with your grandson is the real bonus.

If all Ford does is replace the springs with the original factory types I guess that's all their obligated to do but the multileafs are a nice ride quality upgrade.

 

[Mighty Little Blue]

Just found the forward attach point on the right rear leaf spring fractured on my 2019 Lariat with 62,000 miles. By the appearance, it appears to have been broken for some time. Noted an unusual noise and investigated. I don't live in the rust belt and the undercarriage and components are rust free.

I have the Ford ESP warranty. Called the dealer and they could not tell me if this was under warranty. Its a 25 minute drive to the dealer plus need to inconvenience someone to pick me up after drop of. If under warranty, I would expect they would only fix the right side and not the left. I'm sure there would be an upsell to replace the left side at my cost.

I've looked at the Icon spring aftermarket as an option. I could have a local repair shop do the install or myself. I have all the tools and equipment plus a 16 year old grandson that wants to learn and help his 77 year old grandpa.

Anybody have experience with how Ford deals with a fractured leaf spring under the Ford ESPO warranty ?

Cheers

If Ford does not cover it, I have the ICON and really like them. Some people complain about being noisy, but I have no issues with mine at all. If DIY make sure to do torque with full weight on the springs. They will raise the back depending on which setup you chose option 1, 2 or 3. If you run on the light side I would go with option 1, medium loads option 2, option 3 you need to be at max payload or towing heavy loads.

 

[Titchadesh]

With the proper shop tools it's not super complicated to do and the chance to work with your grandson is the real bonus.

If all Ford does is replace the springs with the original factory types I guess that's all their obligated to do but the multileafs are a nice ride quality upgrade.

2nd on this! Just don’t tow until repaired, order some Icons and have a fun project with your grandson. You’ll be very surprised at the ride quality upgrade. And if Ford decides not to cover, you’ll save money by upgrading as well.

 

[rpeterson53]

2nd on this! Just don’t tow until repaired, order some Icons and have a fun project with your grandson. You’ll be very surprised at the ride quality upgrade. And if Ford decides not to cover, you’ll save money by upgrading as well.

I intended to visit the dealer but after looking at reviews it reminded me why I stopped going there 5 years ago. I figured Ford would only warranty the broken spring and not replace the other side. I got an estimate from a local repair shop for $2400 for both springs using OEM parts.

Just ordered the Icon leaf spring kit from Stage 3 Motorsports. I don't drive the truck much. I use it in summer to haul my 100 pound kayak. I have all the shop tools, etc plus heated garage. I will go to Costco to stock up on ibuprofen plus grandson wants to learn and do this job. To be young again......

Cheers

 

[rpeterson53]

Grandson and i installed the Icon leaf springs yesterday afternoon.

Attached is a photo of the right side leaf spring that fractured at the forward attachment. The other photo is of the left side spring that shows rust at the periphery of the forward attach point bushing. Time on truck is 62,000 miles. Ford Quality.....NONE

It took us about 3 hours elapsed time to replace the springs. Some observations/comments:

1. The Ford shop manual calls to discard all the bolts, nuts, U bolts and shackle bolt. At Ford OEM prices, this is a very significant cost. I did order forward attachment point bolts and a set of the rubber hat bushings just in case. However, on removal of the hardware, it was in like new condition. I don't live in the rust belt and rinse the underside of the vehicle during winter months. The only rust evident on my truck underrcarriage was at the leaf spring forward bushing as shown in the photos.

2. The Icon spring set with hardware cost $850. I bought Daytona 6 ton jackstands $86. Ford OEM hardware I purchased $95 with expedited shipping but did not arrive in time so not used. Future alignment cost $130 after a few hundred miles. Total $1161 for the job vs $2400 price quote from independent shop.

3. I installed the option 1 spring stack that Icon states will raise the rear .375 inches. I have the Ford leveling package. The amount of negative rake is obvious now. Lift is definitely more than .375. Possibly this will decrease with time. Not an issue for me.

4. The right side is .375 inches higher than the left side. I did install the factory shim at the left leaf installation. For those with OCD, maybe a concern. Today driving I noted many pickup trucks don't have perfect ride height at the bed. Mine may have had that before but just never noticed it.

5. My truck is a SuperCab with the 6 foot bed. With no load in the bed, I did notice a small degree of what i believe may be light wheel hop when starting from a stop. Depends on the acceleration level. When I had the bike rack and bike installed (about 80 lbs at the tow receiver), this phenomena was not noted. Truck bed is light and now with more negative rake, might expect this. Not an issue for me since I either have the bike rack or kayak loaded. I may try to find some heavier load to help settle the springs. Not a priority currently.

6. The truck does ride better that the stock springs. I have not noted any squeaking noise, etc. I will be re torquing all the fasteners after 100 miles.

7. One item with the Icon hardware. The U bolts would not slip freely thru the axle lower support plate. Had to slightly open up the end of the U bolt to fit freely. Looks like during manufacture they were bent a bit past 90 degs.

8. Icon instructions do not have the torque values for the attachment bolts. Only the U bolts. I have the Ford Ranger shop manual so I used those values. In addition, Ford called for a torquing sequence of the U bolts that Icon did not detail.

In summary, I'm pleased so far with the install and the cost savings. This is not my primary vehicle so it may be different for others.

Cheers

 

[Racket]

The wheel hop phenomenon is not something I would expect? My understanding is that the monoleafs are stiffer than multis but I wouldn't expect the Icons to introduce that. I don't think the Tremor owners have mentioned it.

 

[Titchadesh]

Grandson and i installed the Icon leaf springs yesterday afternoon.

Attached is a photo of the right side leaf spring that fractured at the forward attachment. The other photo is of the left side spring that shows rust at the periphery of the forward attach point bushing. Time on truck is 62,000 miles. Ford Quality.....NONE

It took us about 3 hours elapsed time to replace the springs. Some observations/comments:

1. The Ford shop manual calls to discard all the bolts, nuts, U bolts and shackle bolt. At Ford OEM prices, this is a very significant cost. I did order forward attachment point bolts and a set of the rubber hat bushings just in case. However, on removal of the hardware, it was in like new condition. I don't live in the rust belt and rinse the underside of the vehicle during winter months. The only rust evident on my truck underrcarriage was at the leaf spring forward bushing as shown in the photos.

2. The Icon spring set with hardware cost $850. I bought Daytona 6 ton jackstands $86. Ford OEM hardware I purchased $95 with expedited shipping but did not arrive in time so not used. Future alignment cost $130 after a few hundred miles. Total $1161 for the job vs $2400 price quote from independent shop.

3. I installed the option 1 spring stack that Icon states will raise the rear .375 inches. I have the Ford leveling package. The amount of negative rake is obvious now. Lift is definitely more than .375. Possibly this will decrease with time. Not an issue for me.

4. The right side is .375 inches higher than the left side. I did install the factory shim at the left leaf installation. For those with OCD, maybe a concern. Today driving I noted many pickup trucks don't have perfect ride height at the bed. Mine may have had that before but just never noticed it.

5. My truck is a SuperCab with the 6 foot bed. With no load in the bed, I did notice a small degree of what i believe may be light wheel hop when starting from a stop. Depends on the acceleration level. When I had the bike rack and bike installed (about 80 lbs at the tow receiver), this phenomena was not noted. Truck bed is light and now with more negative rake, might expect this. Not an issue for me since I either have the bike rack or kayak loaded. I may try to find some heavier load to help settle the springs. Not a priority currently.

6. The truck does ride better that the stock springs. I have not noted any squeaking noise, etc. I will be re torquing all the fasteners after 100 miles.

7. One item with the Icon hardware. The U bolts would not slip freely thru the axle lower support plate. Had to slightly open up the end of the U bolt to fit freely. Looks like during manufacture they were bent a bit past 90 degs.

8. Icon instructions do not have the torque values for the attachment bolts. Only the U bolts. I have the Ford Ranger shop manual so I used those values. In addition, Ford called for a torquing sequence of the U bolts that Icon did not detail.

In summary, I'm pleased so far with the install and the cost savings. This is not my primary vehicle so it may be different for others.

Cheers

Love to see a successful upgrade! My front bushing looked same as yours when I removed it--completely junked. I wonder if in our situations the bushing failed first then the forged eyelet? Or vice versa. Either way, agreed that is not acceptable.

I replaced the bolt and nut on the forward eye on the side that failed just in case it was compromised somehow, but like you observed all of the hardware looked to be in really good shape.

Icon says that the back is supposed to settle down to the .375 increased height, so that will come in time for you. Did you swap out the rear shocks down there while you had it up? I went with Icon's rear 2.0's for the Ranger since I figured they + the new leafs are a balanced ride. My stock shocks were starting to rust so I knew it was time to just start fresh back there.

Sponsored