Ford Raptor Frames Bending - Bed Alignment issue!

Discussion in 'Drive Line' started by BlueSVT, Jun 15, 2011.

  1. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    So some of you may have seem some discussion in other threads, regarding an issue a few members are now having with their beds being out of alignment, and in most cases, the rear end bent downward towards the ground.

    This thread can be used to share information, updates, and ideas for this issue that we're experiencing.

    First, an illustration of the problem. Here is a "Before" picture which illustrates how the truck comes off the factory floor, and the angle at which the bed and windows are lined up:

    [​IMG]

    As you can see, you can draw a straight line from the bed, and it matches right up with the windows. Now, as a comparison, here is an illustration of the issue that some of us have experienced, and the lines drawn for comparison:

    [​IMG]

    And the angle difference:

    [​IMG]

    Clearly, you can see the difference! The rear of the truck appears to be "squatting" for lack of a better term. This happened to a LARGE percentage of the members that participated in the Raptor Run from Barstow to Vegas, as well as members in other states that have had the chance to do some high speed off-road trails.

    What is causing this?

    Well, for now it seems to have been nailed down to one specific problem area. The rear frame, where the bump stop is mounted underneath it. When you're cruising at speed, there is a relatively small amount of rear travel available before hitting the bump stop, when compared to doing something like a full jump, where the entire travel is used.

    When the suspension is pre-loaded a decent amount, there seems to be about 4-5" of travel at the MOST before hitting the bump stop. What's causing the issue, is when hitting a small rut/ditch/kicker at those speeds, which causes the bump stop to be impacted by the rear axle.

    Why such a weakness?

    It appears that the frame in this area is weak for a few reasons. For one, it is not a straight boxed run from front to back, it goes up and gets thinner in this area, to make room for the bump stop. Also, there is a large hole on the inside of the frame, to allow for tooling on the back side of the bump stop nut. This is a SERIOUS weak point, as the frame not only is already misshaped to accommodate for the bump stop, it's not even boxed all around!

    It seems the frame itself is creasing at this point, and causing the whole rear of the truck from this point back, to sag. I was able to run about 90% of the Raptor Run without this occuring on my truck. There was ONE last bump that I hit at about 55MPH (probably about 12" high or less) and soon after I stopped and met up with the other guys, and noticed that indeed I too was affected!

    Here is my truck currently:

    [​IMG]

    [​IMG]

    It's not terrible compared to others. I was lucky enough to have the "least" bent bed of the entire group. Here is a collection of other trucks that have had this same exact issue, they are ALL different trucks, just a lot of black ones!!!:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    There are more, those are just the ones that I personally snapped a photo of. The same problem with all trucks, from the same type of incident. Of the 14 trucks that I drove with a few weeks ago, 10 of them ended up with this same sort of issue. There are more across the country, and I would appreciate those who have this issue to also chime in, and provide information and pictures if you can.

    ... continued
     
  2. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    So, I took my truck to the dealer last week for service and to have them look into this issue. They had my truck for 3 days, and gave me a loaner in the process. They had it sent to the body shop for analysis, and they returned it saying there was no adjustments to be made. They called 3 days later and told me to come look at my truck, they wanted to go over a few things.

    So I arrived, and walked back to the service bay, where they had my truck on a lift. The tech commenced to show me EVERY scratch on the underside of the truck, scratch on the skid plate, scratch on the rear shock protector, etc, etc. Finally, I said "I GET IT... What are you getting at? I didn't come here to have my scratches fixed under warranty".... He said, "Well, it just looks like you drive your truck pretty hard..."

    At that point, I came unglued, and was highly irritated with the guy. I asked for him to show me what qualifies as "hard" use, and how that is judged? A few scratches? Aside from that my truck has NO damage, no actual dents or body damage, clean front to back.

    I then invited him to come inside with me, visit www.ford.com and watch how they drive the Raptor in their advertising and "Design" videos promoting the Raptor. They are professional drivers, I'm an average guy... I do not, and simply CAN NOT drive like they do in those videos...

    So, I was given a customer care number to call, as the dealer says there isn't anything that they "know of" that they can do for the issue. They're not saying I'm not covered, they just have no idea what to do. So I called the rep, and was called back 3 days later. That's where I'm at now! I've been asked to provide more detailed pictures of the issue, as well as other trucks that have had this happen since I mentioned that this is NOT an isolated incident as we are coming to find out.

    On a side note, this is NOT just a results of trucks that ran on the Raptor Run a few weeks ago, I think this is just the first time an entire group of guys that actually took their Raptors out and drove them as advertised, were able to share their findings on the same day... and we realized we have an issue on our hands!
     
  3. runair351

    runair351 New Member

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    Shocked! THat SUCKS man! I can't believe Ford didn't encounter any of this during their testing. I wonder if they added the bump stop later down the road to production? Could a preventative measure be welding in a cover over that tooling hole in the frame?
     
  4. bluesun

    bluesun Member

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    Do you have a picture of the frame where it bent?
     
  5. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    Bed Alignment issue, likely bent rear frame

    I could take one, but there's nothing to really see on mine... It's not clearly visible that it's bent.
     
  6. bluesun

    bluesun Member

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    There was mention that this was more prevalent on Deaver equipped Raptors. Is this rumor or have you found it to be true?
     
  7. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    Bed Alignment issue, likely bent rear frame

    I'm not sure about more prevalent, but I will say the guys with Deavers seem to be bent worse. Could be because of the softer spring load, the impact may be harder on the bump stop.
     
  8. GBrown1867

    GBrown1867 Member Public Safety

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    BlueSVT
    Very well written. Before everyone gets on here and says we "abused" our trucks. Not true at all, we just pushed them to their limits and found a problem with the design of the frame. I have spoken to allot of people/shops regarding this issue and it seems to be a common problem for trucks that are driven hard. It is enough of a problem that a few shops are in the process of designing a way of boxing the frame to help strengthen it. Some may be a bolt on and the others will be a better weld on system.
    As for mine, I am in the place BlueSVT is. My truck has been at the dealer since Monday and I am waiting for the body shop to make a determination as what to do. As of right now I am being the very polite/understanding customer until I get an answer. I am pretty sure they are not going to want to fix it. However, you get 100% of what you don't ask for. So it's worth a try.
     
  9. 19kilo

    19kilo Member Military

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    What kind of bump / impact are we talking about caused the bend?

    If this is not from jumping the truck, I don't see what "abuse" it would be. Driving on rough roads? .... really?

    If its a Baja inspired truck, the roads are rough... the frame needs to be strong enough to support the suspension of the truck. Period.
     
  10. Chrisandalex1

    Chrisandalex1 Member

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    I would really like to see someone engineer a solution to this problem. I would like to do it as preventative measure, as I plan to drive my truck hard. Is anybody looking at a Manufacturer Level? Do we know if the tech guys have chimed in on this yet?

    I am going to be at ADD tomorrow. I am going to ask Jared if he could come up with a solution to strengthen the frame.

    I will have a shit fit if my truck comes back from running in the desert and it looks like that.
     
  11. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    Bed Alignment issue, likely bent rear frame

    Outlaw Raptor has a solution in the works... Boxing in the frame in that area completely. I'm not sure what the status of the fix is, but they're working on it.

    It was NOT from jumping the truck. It happened on trails, at speed.
     
  12. LvRaptorFan

    LvRaptorFan Member

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    Can't wait to hear what ford has to say about warranty on this one! You think this would have come up in R&D.
     
  13. HoustonRider

    HoustonRider Member

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    you sure its the frame? I know frames are built for a certain amount of "flex" from left to right, I'm doubting you could bend it "front to back" unless it dropped from a building.

    Is it possible this is just the suspension (leaf springs) mounts or bed mounts that have flexed and not flexed back? I just have a hard time getting my head around the whole frame is creased. I'm betting the bed moved somehow. If the bed is mounted to the frame and no mounts are torn/broken, why isn't the bed creased?

    I'm not discounting anything, just looking at all angles. Any body shop will have frame specs on file for this truck and could take measurements in a few spots to see if its within limits, or is off at some point.
     
  14. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    Bed Alignment issue, likely bent rear frame

    The rep I've been speaking with is in the process of finding a dealer that has an in-house body shop! Sounds like they're willing to take a step further and hopefully fix it.
     
  15. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    Bed Alignment issue, likely bent rear frame

    I don't think anybody has 100% verified that the frame I doing what we "think" it's doing... At this point I think it's just everybody's best conclusion.

    I'll keep this thread updated with my results from my communications and repairs with Ford.
     
  16. Chrisandalex1

    Chrisandalex1 Member

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    Has anyone documented any physical or visual proof of a bent frame? Has anyone pulled the bed off yet and looked at it?

    Got me thinking about new rear setup.......Hmmmm
     
  17. HighRoller

    HighRoller Member

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    Guys, I would "NOT" do anything until Ford has a chance to look into the issue. This clearly looks like a Manufacture/Design defect and should be handled by Ford. Frame bending is serious, for what ever reason, it can causes all kinds of issues with alighnment, not just the front end either. All things that are mechanical and require a certain alighnment to work and wear properly. I can garranty from looking at the photo's that these trucks have serious issues and may not be safe to drive. Once steel bends it causes micro fractures in the metal, this weakens the area affected and can continue to degrade. Please be safe and watch this closely.
     
  18. Chrisandalex1

    Chrisandalex1 Member

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    I would like to chime in on this for a moment.

    I could not agree more with the outlaw guys. These truck were marketed as being able to handle this kind of terrain. SO THIS IS NOT ABUSE. This is what they were made for.

    This is clearly a design flaw.

    I have not had the pleasure of taking my truck to the desert yet, but I fully intend to be able to push the truck off-road and not worry about the frame being bent. This is what I was sold by Ford. Not a street truck that I can hope will go down a graded dirt road.

    If this is happening with absolutely no other damage to the trucks. This is not abuse. This is a design flaw that Ford needs to step up and address.
     
  19. Chrisandalex1

    Chrisandalex1 Member

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    Plus I don't give a damn if Ford pre-ran anything. They showed me videos of pushing a truck hard as an example of what could be expected as an owner of the Raptor.

    Not a bent frame from a bump in the road.
     
  20. BlueSVT

    BlueSVT Active Member MOTM Winner!

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    For those who have not done so already... please take a minute to view Fords Raptor website, and especially the video section.

    http://www.ford.com/f150raptor/

    After reviewing those, it's pretty damn hard for Ford to say that the "Average Joe" abused his truck off road, when there is NO OTHER damage to the truck. The marketing and design for this truck was aimed precisely at the type of driving and terrain that the "Raptor Run" provided.
     

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