pan hard bracket keep breaking

[23Paddywagon]

On my paddywagon I have a bracket welded to the axle that attaches to the pan hard bar connected to the body/chassis. It has broke three times since putting it on the road. The last time it broke I was returning from Springfield. A good welder came to me and welded the bracket back on and it lasted until last month, about 3 years.
I am wondering if there is something with my configuration/weight that puts unusual pressure on that bracket. I do run it hard through the gears sometimes. I have a '89 mustang 302 with a matching 5 speed transmission, hydraulic clutch.
Any ideas?

[Bruce Pickett]

The ONLY reason I can think of is the weld space is not clean. Paint/rust/dirt or something. Must be down to shiny metal and not tack welded.

If it lasted 3 years without breaking then I suspect something is out of alignment. If it is a straight bar/tube between 2 brackets--1 on rear housing and 1 on frame and the rear radius rods are not broken or loose then I think the rear end housing and the frame are not at a 90*

There should not be any fore or aft movement of the rear end--period. It should move up and down in a slight arc only. If for some reason it is not, then the binding is causing the failure And I don't see how the HEIM joints are not breaking instead of the bracket welds.

You will need to do a string fling of some sort to make sure the frame is square (corner to corner) and that the front end and rear end are parallel to the frame. Then check to see if the frame bracket for the pan hard bar is parallel to the rear end housing bracket, not forwards or backwards from it.

All I can do without seeing the truck.

[23Paddywagon]

Thanks, i will double check those items. I tried to include a picture but what i had was too big.
Can I email you?

[mike wade]

Bob send me the photo and I will post it for you. mdw@....pvtn.net remove the periods……….

[Indycars]

Can you tell which way the bracket is being forced to break? Such as side-to-side or front
to back or some combination? Which way are forces acting that breaks the bracket?

How thick is the metal for the bracket?

[23Paddywagon]

I cannot tell yet what way it has broke. I do know that the bracket was welded to the top of the axle, the welding on the bracket looks like it broke taking the top piece of the axle where it was welded with it. So now there is a hole the size of the bracket base on the top of the axle.

[23Paddywagon]

So from looking at the bracket, it is still attached to the panhard bar, and it looks like it broke from front to back.

[Indycars]

I cannot tell yet what way it has broke. I do know that the bracket was welded to the top of the axle, the welding on the bracket looks like it broke taking the top piece of the axle where it was welded with it. So now there is a hole the size of the bracket base on the top of the axle.

You are right, sounds like there was a good weld then if it pulled metal out of the axle. I assume
the bracket is made from at least 3/16 inch thick or better.

Most of the forces should be acting perpendicular to the sides of the frame and not parallel.
What are you using for the ends of the panhard bar?

Have you checked the other rear suspension brackets and rods for any damage?

[23Paddywagon]

the bracket is 3/8 thick. The bracket broke off the top of the axle housing along the weld. No other damage to suspension bolts/bracket.

[23Paddywagon]

Should i try to flush the axle housing before re-welding the bracket in place? I plan on a cross piece on the bracket and axle housing to give extra support and will make sure the chassis bracket and axle bracket align correctly.