Ok I wasnt too sure where to post this so hopefully this is in the right one. This may be a long post so I apologize if so. Here is where I am at with my truck I have a 2002 F150 5.4 screw.

Engine upgrades:

allen m-90
lightning 90maf
JBA shorty headers
42# injectors
75mm throttle body
+2-3 psi snout pulley
Larger Crank pulley
Volant intake
excalibor 2 from SCT
255 fuel pump
Suspension + Exterior upgrades:

6" Procomp lift
3" Body lift
35" tires
Road Armor huge front bumper + 12k winch
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Ok now for the shorter of the 2 problems My first problem is The suspension
I pretty much have parked this truck for the past 1 1/2 yrs or so Due to the fact that I can literally get about 2-4 weeks out of it before one of my front wheel hubs break off I have replaced a total of 6 not sure how many for each side but both sides have broken. This is a very scary thing to have happen the front wheel literally just falls off while your driving. Held on only by the brake rotor. I have taken the truck to numerous shops and no one can find anything wrong with the suspension, it used to be my daily driver and I know for a fact something is not right with the suspension (OBVIOUSLY). I am fairly mechanically inclined and can find nothing wrong. Is this a common problem? The odd part is that the local FORD dealer keeps the wheel hubs in stock which I find odd. Is the added weight from the bumper winch too much?? I cant imagine but at this point im at my whits end.......

Now for my engine issues. Since I put on the upgrades for the allen supercharger the 42# injectors, 90maf, +2-3 snout pulley and purchased the xcal2 I canot get my truck to run good. It runs like crap. I took it to a local performance shop and had them dyno tune it seemed to run good on the dyno put out good power then as soon as I hopped in it and got on the road it was pinging again. I dont want to blow the engine and I have to keep it literally below 2500 rpm. The local shop I took it to the guy is a real **** and keeps trying to tell me my rings are bad (MY RINGS ARE NOT BAD) it just needs to be tuned by someone who knows what they are doing. I am located in Sacramento/Auburn Ca area I have put so much money in this truck that I dont know what to do anymore basically I have an undrivable money pit I dont want to keep shoveling massive amounts of money in this truck anymore so im literally pulling my hair out. Any help would be appreciated......

 

Sorry to hear about the problems. As far as the Xcal tuning goes surf on over to the Chips and Tuning forum and check out Troyer perfomance. Mike can email you safe tunes. It sounds like your pulley combo could be downgraded to at least the original blower pulley to help with a little less boost in the mean time. Try posting the suspension details in the Suspension forum for better feedback. Good luck.

 

I would tend to believe that it is going to be tough to get that combo to run good for very long, overdriving a m-90 that much creates alot of heat, I would imagine that you are runnnng somewhere around 12 psi of boost? Stock A.E.D runs about 5-6 psi, overdriven pulley= 8-9 psi+ smaler crank pulley ratio = at least 11-12 psi. To much for that small blower in my opinion.
What are your charge air temps looking like? Where is your I.A.T located? Is it in the intake tube, or is it mounted in the manifold AFTER the intercooler?
Without a larger heat exchanger, especiialy in California I would imagine you are seeing actuall I.A.T's around 140 degrees. Hot air charge increases detonation= melted pistons in a blown application.NOT GOOD.
I would ditch the crank pulley, get a Troyer tune or your preference and possibly a larger fan cooled heat exchanger. You also want your I.A.T mounted in the supercharger plenum AFTER the intercooler so the processor can calculate actual air charge temps and control spark advance properly. You can safely and dependably run 8-9 psi with the mods you have and a larger heat exchanger with a good tune.
As for the wheel hub situation, that is and odd one. Are you running really deep offset wheels? This a 4x4 correct? Does the pro comp kit have different spindles than factory?The nut that reatins the cv axle should keep the flange intact even if the bearing completly fails. Do you mean studs are breaking or the whole hub. I need some pics to get a better idea of what is actually going on. I work on lots of these trucks and can't say that I have ever seen that type of issue become an epidemic. Something is not correct, either with the install, or the aftermarket spindle/wheel combo. I don't think the winch is to blame.
Hope this helps....