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Old 08-15-2017, 08:36 AM
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Teraflex Falcon Nexus EF 2.1 Stabilizer came off at track bar

Hi everyone

I installed a new Teraflex Falcon Nexus EF 2.1 Stabilizer a few weeks ago. Yesterday driving about 60 on the highway it popped out causing the track bar to come completely disconnect. Luckily myself and the Jeep survived the experience.

So what happened? I thought I would just be able to replace the bolt and reconnect it to the track bar, but when I got it home and went to do that it turns out the nut completely warped the threading on the bolt connected to the stabilizer. I replaced the old stabilizer because it was completely bent.

What could cause this to happen? At first I thought maybe I did something wrong when I installed it, but considering how simple the installation is, I'm wondering if there is another problem that caused this to happen and possibly caused the previous one to bend. Or is it possible it was the part itself? Though, I doubt it is.

I've only had the jeep for about six months and am trying to get it back up to where it needs to be.

So has anyone else seen similar symptoms?

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Old 08-15-2017, 08:45 AM
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Some background on the Jeep. 08 Unlimited X. No lift. Stock tires. Stock everything really. 130k miles.

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Old 08-15-2017, 08:46 AM   #3
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Never seen or heard of anything like this. Can you post some pictures? Also, I am sure it is a typo but did it just come off the Tie Rod or did the Tie Rod come completely off? Not sure how the Tie Rod would come off the knuckles just because the SS came off?

-Jason
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Old 08-15-2017, 08:59 AM
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ooof! Yes I'm sorry, that is a typo. I mean the track bar not the tie rod. I'm still drinking my coffee...
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Old 08-15-2017, 09:19 AM
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Here are images of the stabilizer that the nut pulled off from.
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Old 08-15-2017, 09:47 AM   #6
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ooof! Yes I'm sorry, that is a typo. I mean the track bar not the tie rod. I'm still drinking my coffee...
How did the track bar come off? The track bar has nothing to do with the stabilizer. Did the track bar bracket brake?

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Here are images of the stabilizer that the nut pulled off from.
Looks like the bolt with the damaged threads, looks like it was cross threaded and damaged when it was installed. This weakend the connection point. So, when it failed, it looked like it pulled the threads flat.

-Jason
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Old 08-15-2017, 10:09 AM   #7
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Yea it looks like when you installed the nut you cross threaded it and never had it properly torqued which caused it to fail.
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Old 08-15-2017, 10:36 AM
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Well these were my initial thoughts. As far as it not being torqued properly anyways. Didn't think about it possibly being cross threaded though.
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Old 08-15-2017, 11:03 AM   #9
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How did the track bar come off? The track bar has nothing to do with the stabilizer. Did the track bar bracket brake?

-Jason
I'm not 100% sure Jason, but I think these new Falcon Steering stabilizers mount at the axle side using the trackbar mounting location. The bolt actually replaces the trackbar bolt instead of using another mounting location or bracket on the axle end.

Not a big fan of that design personally.

EDIT: I'm guessing the Fox ATS does the same? Never knew, I never looked into one...
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Old 08-15-2017, 02:08 PM   #10
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Make sense if the SS replaces the stock Track Bar bolt. Never installed one of the new Falcon SS's but it could happen I guess.

-Jason
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Old 08-15-2017, 02:28 PM   #11
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Read the review here on Quadratec, could that be a problem?
https://www.quadratec.com/p/teraflex...ep-wrangler-jk
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Old 08-15-2017, 03:32 PM   #12
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I have the 2.2 mine came with a nyloc nut already on it so I used that with an added washer. Getting proper tourqe on that thing is a pain. Better have a crows foot and understand how that extension changes the tourqe, there are plenty of calculators online. Terflex calls for 80 ft lbs but according to them thats just so you dont slip and hurt yourself going higher. So I opted to shoot for the 125 mark and with a helper finally made it.

My guess is others are right either it was cross threaded or under torqued or maybe both.

Glad neither you or your jeep was hurt.

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Old 08-15-2017, 05:32 PM
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So here is an update. Yes this steering stabilizer does mount directly to the track bar. I bought a new bolt and connected the track bar with no stabilizer at all and took it for a drive. Everything seemed fine for a bit. Got up to around 50 mph at one point and felt a shimmy in the steering wheel but didn't feel terrible. Then on my road back home at about 35 mph I had the same thing happen again, which I can only describe as DW. Wheels screeching, steering wheel jerking back and forth and the entire body shaking. However this happened without the track bar coming disconnected.

After reading the review that was previously posted, yes I used the factory nut as was suggested by Teraflex. So what I am thinking is that I have a case of death wobble being caused by something else that maybe resulted in the entire bolt being torn off the steering stabilizer because it may not be the right size when the wobble happened at a high speed. I'm just taking a swing here.

There are also a series of warning lights showing now as well that from what I can see is warning of there being a problem with the alignment. ABS, Brake, ESP.

Needless to say, I am going to take it up to my local mechanic and have them take a look and go from there. As much as I would like to try and fix it myself, after my experience on the highway, I would rather have an expert take a look at it.
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Old 08-16-2017, 08:53 AM   #14
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Quote:
Originally Posted by SteelReaperJK View Post
So here is an update. Yes this steering stabilizer does mount directly to the track bar. I bought a new bolt and connected the track bar with no stabilizer at all and took it for a drive. Everything seemed fine for a bit. Got up to around 50 mph at one point and felt a shimmy in the steering wheel but didn't feel terrible. Then on my road back home at about 35 mph I had the same thing happen again, which I can only describe as DW. Wheels screeching, steering wheel jerking back and forth and the entire body shaking. However this happened without the track bar coming disconnected.

After reading the review that was previously posted, yes I used the factory nut as was suggested by Teraflex. So what I am thinking is that I have a case of death wobble being caused by something else that maybe resulted in the entire bolt being torn off the steering stabilizer because it may not be the right size when the wobble happened at a high speed. I'm just taking a swing here.

There are also a series of warning lights showing now as well that from what I can see is warning of there being a problem with the alignment. ABS, Brake, ESP.

Needless to say, I am going to take it up to my local mechanic and have them take a look and go from there. As much as I would like to try and fix it myself, after my experience on the highway, I would rather have an expert take a look at it.
If you can trust your mechanic, that's a good call...at least he can see if there was any other damage or misalignment caused by the SS & trackbar breaking loose at speed.

Given your description of the incident when the stabilizer broke free, I'd be taking a hard look at the holes on the axle trackbar mounting bracket (maybe wallowed from the SS working itself loose) and/or the sleeve/bushing on the trackbar itself is now damaged causing the DW you are describing.
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Old 08-16-2017, 09:25 AM   #15
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Here’s a quick picture of the nut after my install issues of the Nexus EF 2.1 stabilizer. I never even got to drive mine down the road. Before I reached the torque spec the nut or the bolt stripped. The threads still exposed did not appear cross threaded to me.

Long story short, it took a long time to get that stripped bolt off and in the process I damaged the stud extensively. Trust me I tried everything to avoid having to split the nut but that is what it came to. Pretty difficult space to get to.

I used the nylock nut provided by TF. TF is going to rebuild the pressed stud for me. For the time being I am running without a stabilizer and my jeep drives fine. Pretty frustrating to have significant issues like this with something I really didn’t need. I am not a fan of the SS utilizing the axle side trackbar hole.




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Old 08-16-2017, 01:10 PM   #16
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If you had that much difficulty backing the nut off it sounds like you did cross thread the nut.
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Old 08-16-2017, 05:42 PM   #17
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If you had that much difficulty backing the nut off it sounds like you did cross thread the nut.
He would have a heck of a time cross-threading that nut all the way on, the nut probably couldn't take the torque and stripped out. Looks like the grade of hardware isn't up to the task.
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Old 08-16-2017, 06:42 PM   #18
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I'm curious and concerned a bit what's happening here. I managed to make it per teraflex's 80 ft lbs specs overtorqed to 125 ft lbs. Seemed to take the torque well using the provided nylock nut, hasn't blown out or came loose in 4-500 miles. I wonder what's happening.. I agree getting a cross threaded nut all the way down would be tough. Wonder if some of these studs had some quality issues? Anyone heard anything from teraflex on what the root cause might be?
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Old 08-16-2017, 07:03 PM   #19
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Well I guess I will find out Labor Day weekend because I have one of these sitting in my garage and I'm going to put a new lift on my jeep. I still am confused why people are having such a hard time even installing this piece of equipment. The torque is 80 foot pounds and even at the high-end 125 foot pounds, just take some box end wrenches and tighten it down till you fart.
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Old 08-17-2017, 09:32 PM   #20
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I agree 100%. This was one of those times you head out to do a simple task that should take no time at all and end up with a disaster. I’ve personally done 100% of the install work on my jeep and thus far this has been the only issue. Something was bound to happen I guess.

I have the proper tools to do all this stuff such as crows foot 21mm and torque wrench. I’m glad others installations went as expected. I’m sure my situation is an anomaly.


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Old 08-17-2017, 09:43 PM   #21
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In case anyone needs to know, the nut is an M14x1.5


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Old 08-17-2017, 10:44 PM
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Latest update:

I clearly have a case of death wobble and I now am almost certain that this is what resulted in the the stabilizer coming loose.

Here is the current situation. Ball joints and control arm bushings have been replaced. Alignment done. Tires balenced and inspected. Track bar is tightened and torqued (without and steering stabilizer installed currently). These fixes have resulted in what I can honestly say is the smoothest ride I've had since I bought the jeep, under 45mph. No shake in the body or steering whatsoever.

However, at 50mph the body begins to shake and 52mph goes into full on wobble mode until I slow to around 10-15mph. This is consistent every time. No bumps or turns involved, the shaking is violent, tires screeching on the road and steering wheel fly's back and forth. No question it's DW.

I do believe the previous issue with the stabilizer is it disconnected from the track bar due to the shaking and the incorrect nut being used. That being the factory nut that connected was on the track bar before installing the stabilizer. Some good news is that Teraflex has told me that if I send the part back they will fix it free of charge and have it back to me in about two days.

Now on to the next fix.
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Old 08-17-2017, 10:53 PM   #23
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Well the good news is there isn’t a whole lot left to check. Check that all bolts are torqued down (you mentioned trackbar so maybe you’ve done all the other bolts already). How do the tie-rod ends and drag link ends look?


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Old 08-18-2017, 08:32 AM   #24
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Quote:
Originally Posted by SteelReaperJK View Post
Latest update:

I clearly have a case of death wobble and I now am almost certain that this is what resulted in the the stabilizer coming loose.

Here is the current situation. Ball joints and control arm bushings have been replaced. Alignment done. Tires balenced and inspected. Track bar is tightened and torqued (without and steering stabilizer installed currently). These fixes have resulted in what I can honestly say is the smoothest ride I've had since I bought the jeep, under 45mph. No shake in the body or steering whatsoever.

However, at 50mph the body begins to shake and 52mph goes into full on wobble mode until I slow to around 10-15mph. This is consistent every time. No bumps or turns involved, the shaking is violent, tires screeching on the road and steering wheel fly's back and forth. No question it's DW.

I do believe the previous issue with the stabilizer is it disconnected from the track bar due to the shaking and the incorrect nut being used. That being the factory nut that connected was on the track bar before installing the stabilizer. Some good news is that Teraflex has told me that if I send the part back they will fix it free of charge and have it back to me in about two days.

Now on to the next fix.
Did you check the axle end trackbar mounting holes to see if they are wallowed out/ovaled? How does the trackbar bushing/sleeve look at the axle end?

Based on the fact that the SS and subsequently the trackbar worked themselves loose while driving at 60mph, I would have bet both the TB holes and the TB bushing/sleeve at the axle end are damaged enough to cause enough slop for the DW you are describing.

If not, just start knocking the usual suspects off the list, wheel lugs tight? Wheel lug studs bent? You said your ball joints are good. Check TB at frame end too, tie-rod joints tight, Drag link at both ends etc.

One question...you said you are sure the shake/DW caused the SS/trackbar failure. So are you saying you had DW before you installed the stabilizer and was hoping the Falcon SS would 'fix' it??? Or did the DW start after installing the stabilizer and you still have it now that it's removed? If it's the later I'd still strongly suspect the TB mounting holes/TB bushing at axle end are damaged.
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Old 08-18-2017, 09:11 AM   #25
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Your stabilizer did not come with a not attached to the stud. I just went and looked at mine in the box and it has a nylon not attached to the top of the stud to use in place of the factory one
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Old 08-18-2017, 12:16 PM   #26
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@SteelReaperJK Make sure to get that DW sorted before putting the stabilizer on it. A stabilizer shouldn't be used to fix steering issues like DW. I agree with @JeepR kReapR I'm thinking something is worn either prior or after the fact causing your continued DW. Checking for ovaling of those mounting holes might locate your problem.

When someone gets the replacement part can you report back if anything seems different about the stud like stud type, shape or color? Curious if there was a mistake in earlier models that was changed.
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Old 08-19-2017, 09:49 AM
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One question...you said you are sure the shake/DW caused the SS/trackbar failure. So are you saying you had DW before you installed the stabilizer and was hoping the Falcon SS would 'fix' it??? Or did the DW start after installing the stabilizer and you still have it now that it's removed? If it's the later I'd still strongly suspect the TB mounting holes/TB bushing at axle end are damaged.
No I did not have what I would consider DW before replacing the stabilizer. There was some shake in the steering and body but nothing like what I am experiencing now. I replaced the old one because it was badly bent when I bought it.

As for the nut that came with the stabilizer, I did not use it per the installation video from Teraflex as seen here: https://youtu.be/6Xd1-6-nkzs?t=3m4s
They recommended using the factory nut on the track bar if possible.
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Old 08-19-2017, 10:08 AM
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Did you check the axle end trackbar mounting holes to see if they are wallowed out/ovaled? How does the trackbar bushing/sleeve look at the axle end?
Just looked at the bracket and yes it does look wallowed out. Needless to say, I am not doing anymore work on it at this time. I've made an appointment to take it in on Monday to have a pro look at it. I like doing minor repairs but I know when I'm in over my head. I'm not a mechanic. lol.

I will keep everyone updated on what the problems are.
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Old 08-19-2017, 11:35 AM   #29
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seeing the OPs occurrence as well as others all over social media and web. Yet another where at least this guy caught it and concocted a solution that, well, I still wouldn't feel comfy running it in this manner but it is what it is.

Made it work, looks little funny but it works! @TeraFlex suspension @falcons hocks you guys have got - brendan_ricketson

fwiw,Fox has for it's ATS has a monster billet,stainless through bolt in 9/16 that would take a bomb to destroy; maybe these folks could order those?

in my opinion, SS or ram for hydraulic assisted should always be in double shear;I would only ever have its axle connection via dual tabs welded to front of TB bracket for strength and independence from the front TB bolt which is a point of some of the highest stresses to take place upon the suspension.
Not sayin I am right, just an opinion and Ill add that anyone runnin' that type of through bolt & in that manner, should be careful & check it.


(edit: I just realized I did not notice something;
is that stud on the axle side end of the Falcon stabilizer - the one in question & that is sent thru the trackbar bracket and endlink of the trackbar itself - non-removable or permanent ?
If so, that is no bueno..
)
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Old 08-19-2017, 11:54 AM
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seeing the OPs occurrence as well as others all over social media and web. Yet another where at least this guy caught it and concocted a solution that, well, I still wouldn't feel comfy running it in this manner but it is what it is.

Made it work, looks little funny but it works! @TeraFlex suspension @falcons hocks you guys have got - brendan_ricketson

fwiw,Fox has for it's ATS has a monster billet,stainless through bolt in 9/16 that would take a bomb to destroy; maybe these folks could order those?

in my opinion, SS or ram for hydraulic assisted should always be in double shear;I would only ever have its axle connection via dual tabs welded to front of TB bracket for strength and independence from the front TB bolt which is a point of some of the highest stresses to take place upon the suspension.
Not sayin I am right, just an opinion and Ill add that anyone runnin' that type of through bolt & in that manner, should be careful & check it.


(edit: I just realized I did not notice something;
is that stud on the axle side end of the Falcon stabilizer - the one in question & that is sent thru the trackbar bracket and endlink of the trackbar itself - non-removable or permanent ?
If so, that is no bueno..
)
This makes me want to go back to a normal stabilizer to be honest. I guess I did't realize how abnormal this design was. Just figured this track bar mounting would be normal with aftermarket stabilizers.

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