I REALLY Broke my Bronco - Rear Trail Arms

[Poolmanz Sport Bronco]

S’up Sportsters! It all ends well but I want to share my experience of really breaking BOTH my rear trail arm/knuckle attachments to the unibody rails.

Disclaimer: This is NOT the recommended “factory fix” from FORD. The views and thoughts expressed here are not that of FORD or given as expert advice to a permanent fix. This is my own experience for educational and anecdotal purposes.

This year, 2025, I attended the Bronco Safari in Vernal, UT. I was the only Sport at the event. I ran trails rated 2, 3, and 4. I had a great time and judiciously picked my lines. They are organized for safety and have great Trail Bosses as well. Besides some pinstriping, rock sliding, and a smashed exhaust pipe with some bumper bumps - all was good, no issues.

Heading back to CA, I stopped and did an overnight in Dayton, NV at a friend’s. I decided to do a night run up in the Pine Nut Mountains, BLM, This is where I think the FINAL breakage occurred. I feel this breakage was a result of a series of events that led to that night. Possible hairline fractures were caused at Bronco Safari or at my other previous off-roading adventures. “Ticking time bomb” comes to mind.

The Sport has its limits and I have pushed it hard. I have gone over this in my head and I have concluded this: Any vehicle, AWD or 4x4, will break something if pushed beyond what it was designed for. Social Media has 100’s of thousands of videos and posts to prove that. Driver error or design flaw can also be debated. I admit I was the one who broke my Bronco. Many times I should have been “Crawl’n” rather than “Baja’n”. You will see in the photos the “paper thin” metal that the trail arms are bolted to. Descriptions of “weak point”, “weak support”, and “designed not for off-roading” were heard from others who inspected it.

I was told the “factory fix” is to remove half the vehicle to get to the rails that need to be replaced along with all the trial arm components, etc. There was a high possibility the costs would have totaled my Sport out. I started looking for alternative fixes with or without my insurance coverage. Fortunately, I was able to get an experienced fabricator / car restoration shop to do the repairs in such a tight space. (See Photos).

LESSONS

1. Go Slow, Crawl, Slow
2. Take the time to Air Down for comfort - not a “quick run”
3. Check everywhere on the Sport after off-roading events.
4. Maintain a network of vehicle experts
5. Have a sense of humor and not be quick to take offense. (Ecc 7:9)

I was told the “Marlin Speech” from Finding Nemo, “you can’t do these things but you think you can” and “to get a REAL Bronco” to do what I am doing ...and maybe someday I will. For now, I will continue to take my rig out for off-roading and overlanding. Breaking and repairing are part of the show. She’s not ready for the scrap yard or Pavement Princess status.

My Rig: “Baja Blast”
‘21 First Edition
2.5” HRG Lift with 265’s (not recommended)
HRG Front Skid Plate for FE/Badlands
JCR Under-armor with Rock Sliders

 

[jkernitzki]

Great write-up. Lessons learned, teaching moment, real-world examples, you got 'em all!

How much of a factor do you thing the altered geometry because of the lift and oversize shoes may have played?

 

[Poolmanz Sport Bronco]

Great write-up. Lessons learned, teaching moment, real-world examples, you got 'em all!

How much of a factor do you thing the altered geometry because of the lift and oversize shoes may have played?

Zero

Had 1.5” lift and stock tires before. I was on very very rocky trails and my driving style very aggressive.
However, will be stepping down to 245s next time.

 

[Trist0n]

Sheesh, that’s rough! If I’m understanding correctly it sounds like the breakage is more from repeated hard impacts on the rear suspension from going a wee bit too fast through some rough areas?

 

[MoFoCo]

Pretty easy to see why that came apart... it work hardened that sheet metal and snapped off like the tab on a beer can. With your fix secured at both ends of the bolt it should be way stronger. Seems like it could have easily been built that way from the beginning. Must have been a real b-word to weld in that tight area.

Good on you for finding the limits. Glad it wasn't me!

 

[Escape2Bronco]

Your fix depending on the actual weld prep and penetration should be way stronger than originally designed.

Plenty of stories of those of us with full size Bronco’s breaking stuff too while off road. Driving off road especially when in rocky high clearance/flexing situations is tough on vehicles. Body on frame failures are usually a little easier to fix but then are taken places that usually do more damage. The line “Hold my beer” applies!

 

[Poolmanz Sport Bronco]

Sheesh, that’s rough! If I’m understanding correctly it sounds like the breakage is more from repeated hard impacts on the rear suspension from going a wee bit too fast through some rough areas?

Aye, aye!

 

[Quashish]

Fix looks way stronger. Obviously not pretty but thats such an awkward place to be welding. Its a battle wound

 

[Arthonon]

I'm sorry you had to deal with that, but appreciate your post letting everyone know about the potential problem - definitely something to watch out for. I don't think I'll be taking any extreme trails, but that does look a little more frail than I expected.

 

[fourthgear]

Was the Body lifted to weld ? The saying " ya gotta pay to play " comes to mind .

Have you done a four wheel alignment ?

 

[Quashish]

Was the Body lifted to weld ? The saying " ya gotta pay to play " comes to mind .

Have you done a four wheel alignment ?

it IS the body that was welded.

 

[fourthgear]

Yes it's a unibody . but what had to be removed to get at it ? The paint job & how dirty it was before the repair & the repaint seems to match up real good . Was anything removed from above the welding area in the interior to protect it .

Was any reinforcement done besides weld ? What a job to get at .

 

[Poolmanz Sport Bronco]

Yes it's a unibody . but what had to be removed to get at it ? The paint job & how dirty it was before the repair & the repaint seems to match up real good . Was anything removed from above the welding area in the interior to protect it .

Was any reinforcement done besides weld ? What a job to get at .

I’m gonna answer both your posts here.

you describe the FORD factory fix by taking half the vehicle apart and replace the broken u-channel and railing.

So all welding was done without removing body parts. . Of course all the rear components were removed. Nothing was removed from the interior.

He welding at 3 different points for reinforcing
Planing to do an alignment next oil change and rotation.
Still rides solid .

 

[CaptSolo]

S’up Sportsters! It all ends well but I want to share my experience of really breaking BOTH my rear trail arm/knuckle attachments to the unibody rails.

Disclaimer: This is NOT the recommended “factory fix” from FORD. The views and thoughts expressed here are not that of FORD or given as expert advice to a permanent fix. This is my own experience for educational and anecdotal purposes.

This year, 2025, I attended the Bronco Safari in Vernal, UT. I was the only Sport at the event. I ran trails rated 2, 3, and 4. I had a great time and judiciously picked my lines. They are organized for safety and have great Trail Bosses as well. Besides some pinstriping, rock sliding, and a smashed exhaust pipe with some bumper bumps - all was good, no issues.

Heading back to CA, I stopped and did an overnight in Dayton, NV at a friend’s. I decided to do a night run up in the Pine Nut Mountains, BLM, This is where I think the FINAL breakage occurred. I feel this breakage was a result of a series of events that led to that night. Possible hairline fractures were caused at Bronco Safari or at my other previous off-roading adventures. “Ticking time bomb” comes to mind.

The Sport has its limits and I have pushed it hard. I have gone over this in my head and I have concluded this: Any vehicle, AWD or 4x4, will break something if pushed beyond what it was designed for. Social Media has 100’s of thousands of videos and posts to prove that. Driver error or design flaw can also be debated. I admit I was the one who broke my Bronco. Many times I should have been “Crawl’n” rather than “Baja’n”. You will see in the photos the “paper thin” metal that the trail arms are bolted to. Descriptions of “weak point”, “weak support”, and “designed not for off-roading” were heard from others who inspected it.

I was told the “factory fix” is to remove half the vehicle to get to the rails that need to be replaced along with all the trial arm components, etc. There was a high possibility the costs would have totaled my Sport out. I started looking for alternative fixes with or without my insurance coverage. Fortunately, I was able to get an experienced fabricator / car restoration shop to do the repairs in such a tight space. (See Photos).

LESSONS

1. Go Slow, Crawl, Slow
2. Take the time to Air Down for comfort - not a “quick run”
3. Check everywhere on the Sport after off-roading events.
4. Maintain a network of vehicle experts
5. Have a sense of humor and not be quick to take offense. (Ecc 7:9)

I was told the “Marlin Speech” from Finding Nemo, “you can’t do these things but you think you can” and “to get a REAL Bronco” to do what I am doing ...and maybe someday I will. For now, I will continue to take my rig out for off-roading and overlanding. Breaking and repairing are part of the show. She’s not ready for the scrap yard or Pavement Princess status.

My Rig: “Baja Blast”
‘21 First Edition
2.5” HRG Lift with 265’s (not recommended)
HRG Front Skid Plate for FE/Badlands
JCR Under-armor with Rock Sliders

You are "Bona-Fide!" I salute you!

 

[jkernitzki]

You are "Bona-Fide!" I salute you!

​

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