Any history of failure of rear leaf springs on '02 Lightnings?

I've had a knock/rattle/bang/racket going on under the truck since I bought it (used) in November. The knock happens when I get on it and it seems to be worse in poor traction situations.

Anyway - when I put my new pulley on this past Sunday, I crawled around under the truck to try (again) to find the source. I thought is was exhaust, but it all seems tight.

My driver's side rear leaf looked kinda weird - like a compound bow, but not as exagerated.

Like:
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|
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On its side of course...

At the ends of the flat section at the axle perch, there is rust between the leaves.

Could my knock be axle wrap & wheel hop and could this cause spring weakening / failure?

Thanks,
Herb

 

That doesn't seem right.
Do you own a floor jack so you can raise it up from the frame and look for cracks etc.

Both sides should look the same.

 

Yeah - I may be making more of it than there is, but I don't know.

I'll try to get under there and get some photos uploaded to see if its normal or not. I looked at a buddy's '02 L today and his seemed 'smoother (?)'. More like a continuous curve. He does not drive his as hard or as much, so that may have something to do with it.

Incidentally, the truck seem to sit OK - assuming the stock ***-in-air look is OK - seem to be at the same level on both sides.

Thanks,
Herb

 

Sounds like there is more to it than looks if you can hear it.

Seems logical that if it sits the same as the other side it's not broke.

There is also a hole right wear the spring perch is to keep the stack lined up.
You can't see it unless you take it apart though. Just compare the spring tips on both sides.

There is also the sway bar stuff.

Do you have a spare tire? Could be that stuff flopping around to.

 

I got under the truck tonight and shot a blind photo of each side. These photos are with the truck on all 4 tires in my driveway (slight incline - rear lower).

I also measured from the concrete to top center of the wheelwell - 33" on drivers side, 32-1/2" on passenger side. There is a slight diparity in tire pressure - 34psi on Drivers side, 32psi on Passenger's side that may be adding to this difference.

This is the passenger's side, from the front center area:


And this is the driver's side, also from the front center area:


Is this my imagination, or is there a difference between these two springs?

THANKS ALL!!
Herb

 

Maybee I am stoned, but I think I see it too.

I will have to look under mine and see if mine looks like that too.

 

Yea!!

I'm not alone...

Or I too am stoned...



I also need to look into a new axle shaft seal on the pass. side.

The rear cover is sweating like a mother too.

Herb

 

WOW!

Something ain't right in Denmark!!!

Even if you hit a pot hole or jumped a curb it should spring back or brake a wheel (Or something).

I wonder if you are twisting an axle or something wierd.

It's like it wasn't heat treated right and is deforming? Might have been assembled that way and just taking this long for problems to surface.

I would definitly check the wheel with it jacked up and see if it is turning true. Maybe you could get a dial indicator against the rotor and check it that way to.

How many miles on it Herb? "Warranty"

 

Still has a fair piece of warranty left. I'm at about 28.5k now and I'm the second owner.

I can see my dealer hassling me for the chip and pulley - as if the Sterling 9.75 can't handle a few more ponies.

All physical symptoms point toward axle wrap related action - my know happens more when I've got spotty traction or right at launch.

I've got a couple of other warranty issues piling up (windshield leak, rattling driver's door over bumps - second visit on that one), so I may drop it off during the week next week and see what BS they stir up.

It's at least nice to finally feel un-nuts. Up to now I though I may have been crazy to thing I could twist the spring like that!!

I've never had slicks on it, but I can't speak for the previous owner. This clunk could be why he moved on.

Herb

 

Any comments from Ford techs on this one?

I'd like to know if this is a normal or typical situation, before I talk to the dealer.

Don - did you see anying odd under yours?

What are my options for replacement springs, if the dealer crawfishes on this one?

Thanks,
Herb

 

ttt