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ellsworb 07-04-2008 09:32 PM

HELP! Control Arm Bracket FAILURE!
Hey Guys,

First post here to see if anyone has any experience with the following issue. It seems the right front control arm bracket on the axle has failed on my 2004 Wrangler. The bracket apears to have sheared directly below and parallel to the welds on the axle.

My question to you, after reviewing the pictures, do any of you see this as a warranty issue? The dealer is claiming dammage and quoting $3000 for a new axle, etc. I'm not convinced yet. Looking for some of your opinions on solutions.

Top of the bracket still attached to control arm:

Bottom of axle with bits of bracket still welded on:

Aft of axle and control arm looking forward

Closer shot of axle with bits of bracket still attached (from aft looking forward)

Everyone's help and opinion is GREATLY appreciated!

4point 07-04-2008 09:47 PM

What year is the Jeep? This has happened on very rare occasion before, but usually due to abuse or severe rust. The way those welds are cracked it looks like mfg quality issues. Were you jumping it?

4point 07-04-2008 09:52 PM

If you look at those welds you can see rust in the weld itself. It looks like its been cracked for a little while before it broke.

ellsworb 07-04-2008 09:54 PM

No jumping. Haven't even taken it off road. Its a 2004 Wrangler. The underside is rusty, as depicted in the pictures. I would not consider any of this severe rust. Mostly topical in nature. Other than that, this whole things is a mystery to me. I'm really looking for some ammo to take to the dealer to warranty this.

4point 07-04-2008 10:08 PM

It may not help, but in construction we hire independent testing labs to inspect all of our structural welds. These companies could tell you what the weld quality is/was, and if it was a bad weld they would be probably be able to determine that. This may be a little out of their scope of work though.

Just a thought.

Vector6 07-05-2008 07:19 AM

its not that rare,guys in our jeep club have had that happen.

i doubt they will warranty it...

just buy these and have a shop weld them on and be done with it.

ellsworb 07-05-2008 08:50 PM

oh sweet option. Ok. Question #2. Can anyone RECOMMEND an Off Road shop or any other shop to do this kind of work in Dallas, TX? More specifically, Richland or Addison. I see a couple off road shops listed on Google Maps, but would prefer an actual recommendation before I have it towed over there!

BretStep 07-05-2008 09:10 PM

How many miles are on it? When it comes to stuff like this, sometimes you have to be real firm.
I had a 1991 Ford Ranger with bad body mounts and a frames that corroded completely through within 5 years. The passenger front wheel seperated from the frame and slammed up in the wheel well at 75 MPH one morning on my way to work.
When the dealer told me that there was nothing they could do, I filed out forms with the National Transportation Safety Board and faxed them to my dealers district office. Within two days, the dealer called me to bring the truck in for a body refit and Ford would cover 100% of it.
The NTSB uses data to make auto manufacturers issue recalls, which costs them hundreds of millions annualy.

slf41002 07-05-2008 09:29 PM

Sorry to say but it did not brake at the weld.It has clearly cracked through the steel of the bracket how ever it should still be covered because instead of the weld being weak it was the steel that the bracket was made from.I would just do as Vector said and order the Rusty's brackets and your out $60 plus shipping.Well that is if you could weld but I am assuming that you can not due to the fact U want to find an off road shop.I would not look to an off road shop though I would fined a good reputable shop/garage that does welding and have them grind the old weld off and down and weld the new Rusty's brackets on.However I would have it towed on a rollback or trailered to the shop though cause if the other side is also weak you will end up with allot more damage than you are looking at now if the other side lets loose as well.

Jerry Bransford 07-06-2008 12:27 PM

That happens and it's not a big deal. Just have a new bracket welded in place which can be purchased from places like Rubicon Express, Mountain Off Road Enterprises, Rusty's, etc.. Including the welding it should cost less than $100 to repair. :)

branty 07-07-2008 04:28 PM

I can see where that exact bracket has been rewelded on my 98. Good to know its a cheap repair.

Triple88a 07-07-2008 05:24 PM

What does it say on your warranty sheet? Perhaps take few pics, print them out and go show the dealer with another vehicle of course. You might get lucky. No harm in trying.

1BLKJP 07-07-2008 05:50 PM

Normally I'd say that it's just something that needs to be beefed up. However something you said has me concerned in your case. You stated that you have never taken this vehicle off road? I can't tell from your pics, but do you have a lift on it? I can tell you are still using stock control arms.

Can you enlighten us to what was going on when this happened?

lost 07-07-2008 07:55 PM

this seems to be happening alot lately :D
(c.a. brackets ripping off)

mr4x4 07-08-2008 12:47 AM

its common if they dont brake they bend I replace those brackets all the time
the good news is if you replace the brackets with the aftermarket ones like rubicon express or rusty's Mountain Off Road Enterprises (more)
it wont happen again (as long as the welds hold up)

LWrangler 07-08-2008 12:56 AM


Originally Posted by lost (Post 243776)
this seems to be happening alot lately :D
(c.a. brackets ripping off)

Well, this is what off roading is all about...
Slamming, breaking, crashing and getting dirty...
Oooops I forgt something, Fizxing :crash:...

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