Axle keeps pulling out of hub - HELP!

[Cricket301]

I have a 94 2dr Explorer Sport. It has a 4" suspension lift and a 4" body lift. I'm running 35's with the stock front TTB drive line other than Warn lockout hubs. The passanger side axle shaft keeps pulling out of the hub when I offroad on the aggressive side or when I max out the front suspension and turn at the same time. I checked the axle and it has an indentation in the splines just before the wheel bearing nut. It had no retainer so I questioned my local Ford dealer and bought a retainer "C" clip for it. It clipped on but not very well. That only lasted a short time before it popped off and almost waisted my hub. Does anyone have any suggestions? I was considering drilling a small hole through the shaft just before the wheel bearing nut and using a cotter pin and hardened washer but I wanted a professional opinion first. Can anyone help? ThanX - Randy

 

[zhanx]

how about a limit strap to prevent it from traveling that far in the first place?

 

[Cricket301]

I initially considered the limit strap, however the axle can ride out with out maxing out the suspension. Maybe the limit strap will keep the axle in place when used with the "C" retainer. I could see the issue being that when the suspension is maxed that the axle is pulled too far inward and it is just too much for the retainer to hold back, therefor it fails. I'll give it a shot. Any suggestions where to find limit straps?

 

[Bigcheck1]

Look at the back side of the front suspension. Coming out of the pumpkin you will be able to see the passanger side axle shaft. There is a rubber boot-like thing on the passenger side shaft close to the pumpkin. If my memory serves me correctly there must be some type of clamp around the 2 pieces of the shaft or it pulls apart. Not sure if this is the problem, but i do remember mine pulling out because the metal clamps around the shaft had rusted and broken off.

 

[Cricket301]

I know exactly where your talking about. I checked it and pulled the boot back. There is basically nothing to help push the shaft back toward the wheel. The shaft is able to work it's way in toward the U joint. This may be because the "C" retainer is off of the outside of the axle shaft by the hub. I don't know exactly what configuration the driveshaft it's self must be in.