Front Drive Axle

Manual Locking Hubs

DISASSEMBLY AND ASSEMBLY

Three screws retain the cap to the hub body

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Remove the lockring seated in the groove of the brake rotor assembly

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Remove the hub body assembly from the brake rotor assembly

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1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the three screws retaining the cap and remove the cap from the hub.
4. Remove the lockring seated in the groove of the brake rotor assembly.
5. Remove the hub body assembly from the brake rotor assembly.

To install:

6. The installation is the reverse of the removal.

Automatic Locking Hubs

DISASSEMBLY AND ASSEMBLY

Automatic locking hubs—exploded view

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1. Raise and safely support the vehicle.
2. Remove the tire.
3. Remove the three screws and separate the cap from the body.
4. Remove the lock-ring seated in the groove of the hub assembly.
5. Remove the body assembly from the brake rotor/hub.
6. Remove the snapring from the groove in the stub-shaft.
7. Remove the three thrust washers from the stub-shaft.
8. Pull the cam assembly to remove it.

To install:

9. Align the fixed cam retaining key on the cam assembly with the key-way on the spindle. Firmly push the cam assembly on the wheel retaining nut.
10. Install the metal, plastic, then the splined washers on the stub-shaft.
11. Install the snapring in the groove of the stub-shaft. It may be necessary to push the stub-shaft outward from the back of the knuckle assembly.

12. Rotate the moving cam assembly to the one o'clock position in relation to the fixed cam retaining key. Use any one of the three stops.
13. Install the body assembly onto the hub by lining up the three legs with the three pockets in the cam assembly. Be sure the assembly is in far enough to see the groove in the hub.
14. Install the large lock-ring in the groove on the hub. Ensure the lock-ring is seated completely.
15. Install the cap and tighten the three screws.
16. Install the tire and lower the vehicle to the floor.

Axle Shaft, Bearing and Seal

REMOVAL & INSTALLATION

Dana 50 Independent Front Suspension

1. Raise and support the front end on jackstands.
2. Remove the front wheels.
3. Remove the calipers.
4. Remove the hub/rotor assemblies.
5. Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic mallet to remove it from the knuckle.
6. Remove the splash shield.
7. On the left side, pull the shaft from the carrier, through the knuckle.
8. On the right side, remove and discard the keystone clamp from the shaft and joint assembly and the stub shaft. Slide the rubber boot onto the shaft and pull the shaft and joint assembly from the splines of the stub shaft.
9. Place the spindle in a soft-jawed vise clamped on the second step of the spindle.
10. Using a slide hammer and bearing puller, remove the needle bearing from the spindle.
11. Inspect all parts. If the spindle is excessively corroded or pitted it must be replaced. If the U-joints are excessively loose or don't move freely, they must be replaced. If any shaft is bent, it must be replaced.

To install:

12. Clean all dirt and grease from the spindle bearing bore. The bore must be free of nicks and burrs.
13. Insert a new spindle bearing in its bore with the printing facing outward. Drive it into place with drive T80T-4000-S for F-150 and F-250, or T80T-4000-R for the F-350, or their equivalents. Install a new bearing seal with the lip facing away from the bearing.
14. Pack the bearing and hub seal with grease. Install the hub seal with a driver.
15. Place the thrust washer on the axle shaft.
16. Place a new slinger on the axle shaft.
17. Install the rubber V-seal on the slinger. The seal lip should face the spindle.
18. Install the plastic spacer on the axle shaft. The chamfered side of the spacer should be inboard against the axle shaft.
19. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with heavy duty, high temperature, waterproof wheel bearing grease.
20. On the right side, install the rubber boot and new keystone clamps on the stub shaft and slip yoke. The splines permit only one way of meshing so you'll have to properly align the missing spline in the slip yoke with the gapless male spline on the shaft. Slide the right shaft and joint assembly into the slip yoke, making sure that the splines are fully engaged. Slide the boot over the assembly and crimp the keystone clamp.
21. On the left side, slide the shaft and joint assembly through the knuckle and engage the splines in the carrier.
22. Install the splash shield and spindle on the knuckle. Tighten the spindle nuts to 60 ft. lbs. (81 Nm).
23. Install the rotor on the spindle. Install the outer wheel bearing into the cup. Make sure that the grease seal lip totally encircles the spindle.
24. Install the wheel bearing, locknut, thrust bearing, snapring and locking hubs. See Section 1.
25. Install the caliper.

Halfshaft

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

Remove the front hub cotter pin (1), retainer (2) and nut (3)

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Remove the upper ball joint cotter pin and castle nut

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Remove the two disc caliper mounting bolts, then lift the front disc caliper off of the front disc brake caliper anchor plate and position aside

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Remove the six front halfshaft-to-differential bolts

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Remove the halfshaft from the vehicle

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1. Break the front wheel lug nuts loose while the weight of the vehicle is resting on the front wheels.
2. Raise and safely support the front of the vehicle.
3. Remove the front wheels.
4. Remove the front hub cotter pin, retainer and nut.
5. Using a floor hydraulic jack, support the lower suspension arm.
6. Remove the upper ball joint cotter pin and castle nut.
7. Use a Pitman arm puller, such as Ford Tool T64P-3590-F, to separate the front wheel knuckle from the front suspension upper arm.
8. Lower the lower suspension arm and steering knuckle slightly to facilitate easier halfshaft removal.
9. Remove the two disc caliper mounting bolts, then lift the front disc caliper off of the front disc brake caliper anchor plate and position aside. Do not allow the caliper to hang by the brake hose; suspend it from the vehicle's frame with strong cord or wire.
10. Remove the six front halfshaft-to-differential bolts.

11. Remove the inboard end of the halfshaft from the differential case or extension axle case. Separate the front halfshaft and joints from the hub, then remove the halfshaft and joints from the vehicle.

To install:

12. Slide the halfshaft outboard end into the hub, making sure that the splines engage.
13. Situate the inboard end of the halfshaft against the front differential flange and install the six halfshaft-to-differential bolts. Tighten the halfshaft bolts to 51-67 ft. lbs. (68-92 Nm).
14. Install the front disc brake caliper onto the rotor and anchor plate, then install and tighten the two caliper mounting bolts.
15. Lift the lower suspension arm and steering knuckle up until the upper ball joint stud is inserted into the steering knuckle. Install and tighten the upper ball joint castle nut. Install a new cotter pin.
16. Install the hub nut onto the halfshaft and tighten the hub nut to 188-254 ft. lbs. (255-345 Nm).
17. Install the hub nut retainer and a new cotter pin.
18. Install the front wheels.
19. Lower the vehicle to the ground.

CV-Joints

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

Before continuing with this procedure, make sure to have available a new CV-joint boot kit, for each CV-joint being serviced. The outer CV-joint cannot be disassembled, only the boot can be replaced.

INNER CV-JOINT AND BOOT

1. Remove the halfshaft assembly from the vehicle.
2. Clamp the halfshaft in a vise equipped with jaw caps to prevent damage to machined surfaces. Do not allow the vise jaws to contact the boot or its clamp.
3. Slide 2 inboard clamp protectors off the boot clamps.
4. Carefully remove 2 boot clamps, and slide the boot off the inner CV-joint and housing.
5. Remove the CV-joint retaining ring and remove the housing.
6. Mark the inner race and the ball cage for assembly.
7. Remove 6 cage balls.
8. Remove the snapring.
9. Remove the inner race and ball cage.
10. Clean all parts in suitable parts cleaning solvent and inspect for wear.

To install:

11. Place the boot and the small boot clamp and protector on the shaft.
12. Place the ball cage on the shaft with the tapered end toward the outer CV-joint.

Line up the marks made at disassembly.

13. Position the inner race on the driveshaft in the position marked on disassembly.
14. Install the snapring.
15. Lubricate and position 6 balls with suitable CV-joint grease.
16. Place the boot protector and boot clamp on the CV-joint housing. Fill the housing with 8.29 ounces of suitable CV-joint grease.
17. Place the housing to the cage and bearings and install the retaining ring.
18. Remove any excess grease from the mating surface and position the boot and clamp.
19. Adjust the CV-joint to boot spacing to 16.43 in. (417.25mm).
20. After adjusting the CV-joint to boot spacing, insert a dull bladed screwdriver blade to relieve built up air pressure in the boot.
21. Use CV Boot Clamp Installer T95P-3514-A or equivalent, to install the boot clamps.
22. Place the clamp protectors over the boot clamps.
23. Install the halfshaft into the vehicle.
24. Road test the vehicle and check for proper operation.

OUTER BOOT

1. Remove the inner CV-joint and housing from the halfshaft.
2. Remove the inner boot from the halfshaft.
3. Remove the outer boot clamp protectors and carefully remove the boot clamps.
4. Remove the outer boot from the halfshaft and inspect the grease for contamination.
5. If the grease is contaminated, clean and inspect the joint for wear. Replace the joint and shaft if worn or damaged.

To install:

6. Place the new CV-joint boot on the shaft.
7. Using 5.82 ounces (165 grams) of suitable CV-joint grease, pack the outer CV-joint with grease, then spread the remaining grease inside the boot.
8. Clean the boot mounting surface and position the boot in the joint grooves.
9. Place the clamps in position and use CV Boot Clamp Installer T95P-3514-A or equivalent, to install the boot clamps.
10. Place the clamp protectors over the boot clamps.
11. Install the inner boot on the halfshaft.
12. Install the inner CV-joint and housing on the halfshaft.
13. Install the halfshaft in the vehicle.
14. Road test the vehicle and check for proper operation.

Pinion Seal

REMOVAL & INSTALLATION

Independent Front Axle

After the companion flange is removed, the pinion seal is accessible

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Use a suitable tool to install the pinion seal

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A torque wrench capable of at least 225 ft. lbs. (305 Nm) is required for pinion seal installation.

1. Raise and safely support the vehicle with jackstands under the frame rails. Allow the axle to drop to rebound position for working clearance.
2. Mark the companion flanges and U-joints for correct reinstallation position.
3. Remove the driveshaft. Use a suitable tool to hold the companion flange. Remove the pinion nut and companion flange.
4. Use a slide hammer and hook or sheet metal screw to remove the oil seal.

To install:

5. Install a new pinion seal after lubricating the sealing surfaces. Use a suitable seal driver. Install the companion flange and pinion nut. Tighten the nut to 200-220 ft. lbs. (271-298 Nm).

Monobeam Front Axle

A torque wrench capable of at least 300 ft. lbs. (407 Nm) is required for pinion seal installation.

1. Raise and support the truck on jackstands.
2. Allow the axle to hang freely.
3. Matchmark and disconnect the driveshaft from the front axle.
4. Using a tool such as T75T-4851-B, or equivalent, hold the pinion flange while removing the pinion nut.
5. Using a puller, remove the pinion flange.
6. Use a puller to remove the seal, or punch the seal out using a pin punch.

To install:

7. Thoroughly clean the seal bore and make sure that it is not damaged in any way. Coat the sealing edge of the new seal with a small amount of 80W/90 oil and drive the seal into the housing using a seal driver.
8. Coat the inside of the pinion flange with clean 80W/90 oil and install the flange onto the pinion shaft.
9. Install the nut on the pinion shaft and tighten it to 250-300 ft. lbs. (339-407 Nm).
10. Connect the driveshaft.

Right Side Slip Yoke and Stub Shaft, Carrier, Carrier Oil Seal and Bearing

REMOVAL & INSTALLATION

Dana 50 Independent Front Axle

Right side slip yoke and stub shaft, carrier, carrier oil seal and bearing—Dana 50

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This procedure requires the use of special tools.

1. Raise and support the front end on jackstands.
2. Disconnect the front driveshaft from the carrier and wire it up out of the way.
3. Remove the left and right axle shafts and both spindles.
4. Support the carrier with a floor jack and unbolt the carrier from the support arm.
5. Place a drain pan under the carrier, separate the carrier from the support arm and drain the carrier.
6. Remove the carrier from the truck.
7. Place the carrier in holding fixture T57L-500-B with adapters T80T-4000-B.
8. Rotate the slip yoke and shaft assembly from the carrier.
9. Using a slide hammer/puller remove the caged needle bearing and oil seal as a unit. Discard the oil seal and bearing.

To install:

10. Clean the bearing bore thoroughly and make sure that it is free of nicks and burrs.
11. Insert a new bearing in its bore with the printing facing outward. Drive it into place with driver T83T-1244-A, or its equivalent. Install a new bearing seal with the lip facing away from the bearing. Coat the bearing and seal with waterproof wheel bearing grease.
12. Install the slip yoke and shaft assembly into the carrier so that the groove in the shaft is visible in the differential case.
13. Install the snapring in the groove in the shaft. It may be necessary to force the snapring into place with a small prybar. Don't strike the snapring!
14. Remove the carrier from the holding fixture.
15. Clean all traces of sealant from the carrier and support arm. Make sure the mating surfaces are clean. Apply a ¹/₄ in. (6mm) wide bead of RTV sealant to the mating surface of the carrier. The bead must be continuous and should not pass through or outside of the holes. Install the carrier with 5 minutes of applying the sealer.
16. Position the carrier on the jack and raise it into position using guide pins to align it if you'd like. Install and hand-tighten the bolts. Tighten the bolts in a circular pattern to 30-40 ft. lbs. (41-54 Nm).
17. Install the support arm tab bolts and tighten them to 85-100 ft. lbs. (115-136 Nm).
18. Install all other parts in reverse order of removal.

Spindle and Front Axle Shaft

REMOVAL & INSTALLATION

Dana 60 Monobeam

Spindle cap removal for the Dana 60 Monobeam front drive axle

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Compression spring removal for the Dana 60 Monobeam front drive axle

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Lower kingpin removal for the Dana 60 Monobeam front drive axle

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Axle shift components for the Dana 60 Monobeam front drive axle

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Tapered bushing removal for the Dana 60 Monobeam front drive axle

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Installing the upper kingpin on the Dana 60 Monobeam front drive axle

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Removing the lower kingpin on the Dana 60 Monobeam front drive axle

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1. Raise and support the front end on jackstands.
2. Remove the caliper from the knuckle and wire it out of the way.
3. Remove the free-running hub.
4. Remove the front wheel bearings.
5. Remove the hub and rotor assembly.
6. Remove the spindle-to-knuckle bolts. Tap the spindle from the knuckle using a plastic mallet.
7. Remove the splash shield and caliper support.
8. Pull the axle shaft out through the knuckle.
9. Using a slide hammer and bearing cup puller, remove the needle bearing from the spindle.
10. Clean the spindle bore thoroughly and make sure that it is free of nicks and burrs. If the bore is excessively pitted or scored, the spindle must be replaced.

To install:

11. Insert a new spindle bearing in its bore with the printing facing outward. Drive it into place with driver T80T-4000-R, or its equivalent. Install a new bearing seal with the lip facing away from the bearing.
12. Pack the bearing with waterproof wheel bearing grease.
13. Pack the thrust face of the seal in the spindle bore and the V-seal on the axle shaft with waterproof wheel bearing grease.
14. Carefully guide the axle shaft through the knuckle and into the housing. Align the splines and fully seat the shaft.
15. Place the bronze spacer on the shaft. The chamfered side of the spacer must be inboard.
16. Install the splash shield and caliper support.
17. Place the spindle on the knuckle and install the bolts. Tighten the bolts to 50-60 ft. lbs. (68-81 Nm).
18. Install the hub/rotor assembly on the spindle.
19. Assemble the wheel bearings.
20. Assemble the free-running hub.

Axle Housing Assembly

REMOVAL & INSTALLATION

F-150, F-250, Expedition and Navigator

Remove the front differential support

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Tighten the front differential support bolts as shown

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1. With the transmission in Neutral, raise and support the vehicle.
2. Index-mark the front driveshaft to the axle universal joint flange.

3. Disconnect and support the front driveshaft.
4. Remove the six bolts and disconnect the front drive halfshafts on both sides.
5. Disconnect the vacuum lines and the front axle vent tube.
6. Use a high-lift jack to support the axle assembly.
7. Remove the front differential supports.
8. Carefully lower the front drive axle assembly.
9. Installation is the reverse of the removal.

Dana 50 Front Axle

1. Raise and support the front end on jackstands placed under the radius arms.
2. Remove the wheels.
3. Remove the calipers and wire them out of the way. Don't disconnect the brake lines.
4. Support the axle arm with a jack and remove the upper coil spring retainers.
5. Lower the jack and remove the coil springs, spring cushions and lower spring seats.
6. Disconnect the shock absorbers at the radius arms and upper mounting brackets.
7. Remove the studs and spring seats at the radius arms and axle arms.
8. Remove the bolts securing the upper attachment to the axle arm and the lower attachment to the axle arm.
9. Disconnect the vent tube at the housing. Remove the vent fitting and install a ¹/₈ in. pipe plug.
10. Remove the pivot bolt securing the right side axle arm to the crossmember. Remove and discard the boot clamps and remove the boot from the shaft. Remove the right drive axle assembly and pull the axle shaft from the slip shaft.
11. Support the housing with a floor jack. Remove the bolt securing the left side axle assembly to the crossmember. Remove the left side drive axle assembly.
12. Installation is basically a reversal of the removal procedure. Always use new boot clamps. Observe the following torques:

• Left and right drive axles-to-crossmember: 120-150 ft. lbs. (163-203 Nm)
• Axle arm-to-radius arm: 180-240 ft. lbs. (244-325 Nm)
• Coil spring insulator: 30-70 ft. lbs. (41-95 Nm)
• Upper spring retainer: 13-18 ft. lbs. (18-24 Nm)

Dana 60 Front Axle

1. Raise and support the front end on jackstands placed under the frame.
2. Remove the wheels.
3. Remove the calipers and wire them out of the way. Don't disconnect the brake lines.
4. Disconnect the stabilizer links at the stabilizer bar.
5. Remove the U-bolts securing the stabilizer bar and mounting brackets to the axle.
6. Remove the cotter pins and nuts securing the spindle connecting rod to the steering knuckles. Separate the connecting rod to the steering knuckles. Separate the connecting rods from the knuckles with a pitman arm puller. Wire the steering linkage to the spring.
7. Matchmark and disconnect the driveshaft from the front axle.
8. Disconnect the vent tube at the axle and plug the fitting.
9. On the right side, disconnect the track bar from the right spring cap.
10. Raise the front end and position jackstands under front springs at a point about half way between the axle and spring rear hanger. Remove the jackstands from the front of the frame and lower the truck onto the stands under the springs. Make sure that the truck is securely supported.
11. Support the axle with a floor jack.
12. Remove the U-bolts securing the springs to the axle.
13. Lower the axle from the truck.

To install:

14. Installation is the reverse of removal. Observe the following torques:

• Driveshaft-to-flange: 15-20 ft. lbs. (20-27 Nm)
• Track bar nut and bolt: 160-200 ft. lbs. (217-271 Nm)
• Stabilizer link nut: 20-30 ft. lbs. (27-41 Nm)
• Stabilizer bar U-bolt: 50-65 ft. lbs. (68-88 Nm)
• Spindle connecting rod-to-knuckle: 70-100 ft. lbs. (95-136 Nm)
• Front spring U-bolts: 85-100 ft. lbs. (115-136 Nm)

Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning.