So after going out to the trails yesterday the bracket connecting my left upper control arm to my rear differential broke off at the weld, as shown in the pictures. This is now the third time I have had this problem on one side or the other, and after last time I even had the gussets added, as seen in the pictures. I did a search and was not able to find any other threads about this, but there is clearly some problem with my setup that is causing this to happen (I have a 4" suspension lift). I am pretty sure these are what I need to fix the problem, but I wanted to confirm that this will fix my problem before I spend that much money http://www.allprooffroad.com/90954runnerrearsuspension

 

that weld looks wellll not that good, you may be better off in the long run just to spend the $200

 

Looks like it's time for a rear leaf suspension.... j/k that sucks sorry to hear it.
I second that the welds aren't penetrating enough..

 

X2 on the weld, the top one looks very porous, its kinda hard to see but, my guess is it looks worse in person.
Try having an experienced shop redo the welds and gussets.
No offense but I weld and fabricate as part of my job and when I have something super critical I call in the big boys that do it every day for 20-30 years, that's all they do..........my stuff is very good....theirs is like artwork.
To me I would think that area of your rig is very critical and you should not be shy on spending some bucks to have a real good shop help you out.

 

I actually paid someone to do those welds and gussets, as I do not have a welder or much experience welding. Since it is the third time this has happened I am wondering if having my stock lower control arms on my lifted truck simply puts too much pressure on those joints when I am 4-wheeling. I am not sure that better welds alone will solve the problem.

 

did you do a panhard drop bracket?

 

Those welds are garbage. Looks like an 8 year old welded it.

And the reason they are breaking off, besides the obvious weld issue, is the added leverage you have put on it with the drop bracket lift. I would have someone weld that Correctly, and then get those arms with the johnny joints so there is less twisting force placed on the mounts.

 

The way it broke makes me think it was poorly welded. I think it needs more weld penetration. Are you sure that it wasn't brazed or something That said, there is a tonne of extra leverage on the bracket that it wasn't designed for. I think you either have to redesign the 4 link setup or go leaf springs for a reliable set up.

 

I agree....that those welds are poor...sorry to hear you paid for those.

I see a problem with that pivotable shackle on top of the bracket....what the hell is that all about that is non-functional in doing what it needs to do.

edit---ok...I see that the shackle is not a shackle...that it is bolted down below and it is "fixed" like it should be. I also agree that it is causing excessive leverage on the housing welds. Better welds and better bracing to the housing are needed(not just that simple triangle brace).
ZUK

 

X10000

Crappy welds, take it somewhere else.
Mine broke when mine was stock welded them up and have been fine since..

 

additional note--- the way that triangle brace was positioned did very little for actually bracing it up.....a poorly positioned brace. It needs a strong MIG weld on the backside where the brakeline is bolted to....it also strongly needs a long rectangular plate on the frontside.

 

Here's what a great front brace would look like

 

I bet Steve Schaeffer could fix it up right.

 

DING DING DING!
I bet you wouldn't lose money on that bet.
http://www.sonoransteel.com/

 

Awesome, thanks. I will definitely give him a call.

 

I know it's been several years, but I was wondering how this went? I broke my passenger side yesterday.