I have a 06 ram1500 with a 6'' lift and a leveling kit and the front axle housing keeps cracking. Its made of Aluminum. This is the 2nd time it has happened in the past 2 months and it cost me 1400 to have it fixed the 1st time. It is a ZONE lift which is made by BDS (a good lift you would think) and was professionally installed. I have had another shop look at it as well to make sure everything was done right. They said everything was good but here i am again with the same problem. My truck never gets driven hard and has never seen the mud. I baby the hell out of it. I just don't understand why it keeps cracking. ANY HELP WOULD BE GREATLY APPRECIATED!!!! thanks

 

Where is it cracked?

 

The first time it broke on the axle tube right out of the hoghead passanger side. This time it broke where it bolts up to The drop down mount on the lift kit (Passenger-side as well)

 

That is weird. Maybe your cvs are on too much of an angle and it's trying to pull down on the differential

 

But two Different shops said everything looked okay. I think I'm going to try to Weld the axle housing back together and take the leveling kit off and hopefully this won't happen again.

 

I know this is an old thread but did you ever figure out the problem? My 2007 did it too.