A dumb D35 question.

[8594]

Man I need the frame specifications and all the Ford shop manual has is the body mount specs.

I do think that after all this time I just might have a grasp...
Just because something lived don't mean it wasn't imposable for it to have done so...

Ignoring the fact that after the lift it rolled on 40,000-miles...

Because I am out of ideas I started measuring.
I set both beams to the same height off the floor as measured at the steering arm. A little below ride height but equal.
I eyeballed both knuckles straight, not turned right or left.
I put a straight edge on the spindle pad and measured to a point on the frame that is about the same place on both sides.
In the semi-darkness I'm getting 5/8-inch difference, with the drivers side knuckle closer to the frame then the passenger side.
Moving the drivers side out would shorten the 15 3/4" number back towards 15 AND it would spread the slip yoke apart by the same amount.

It would also explain some other stuff that went on when the lift was installed back in 2003...
Wonder what Duff's warranty is on a screwed up drop bracket 5 years later?

 

[4x4junkie]

I seem to recall their warranty was lifetime to the original purchaser (most others are), but you'd have to call & confirm.

Check that the inside of the frame crossmember where the rear part of the bracket is bolted isn't bent.

 

[8594]

I seem to recall their warranty was lifetime to the original purchaser (most others are), but you'd have to call & confirm.

Check that the inside of the frame crossmember where the rear part of the bracket is bolted isn't bent.

I've gone over this truck thoroughly at this point, The James Duff Bracket is simply made 3/4" out of position. I called JD and spoke to them and they have not made any changes to the brackets. It could be that this one is the only one that is FUBAR or it could be that they made a change and the person I spoke to does not know about that change or it could be that all their brackets are all like this.
In any case I'm just going to weld this up and move the hole to where it should be, it is faster and less of a PITA then dealing with getting a replacement from JD.

I would like to thank everybody again for your help with this rather frustrating diagnoses of the fault in this truck!

 

[4x4junkie]

No problem... Good luck on it

 

[8594]

Life is in the way of getting this done but I have re-drilled the hole and the axle fits!

Now I just need the time to do some welding.

 

[8594]

I finally got it back on the ground today!

One more minor thing.
I ended up slicing 5/16" off the rear lower dual shock mount which will pull it back out of the tire at full lock by about 3/16".
Things clear so much better now!!