REMOVAL & INSTALLATION
F-150, F-250, Expedition and Navigator
- Break the front wheel lug nuts loose while the weight of the vehicle is resting on the front wheels.
- Raise and safely support the front of the vehicle.
- Remove the front wheels.
- Remove the front hub cotter pin, retainer and nut.
- Using a floor hydraulic jack, support the lower suspension arm.
- Remove the upper ball joint cotter pin and castle nut.
- Use a Pitman arm puller, such as Ford Tool T64P-3590-F, to separate the front wheel knuckle from the front suspension upper arm.
- Lower the lower suspension arm and steering knuckle slightly to facilitate easier halfshaft removal.
- 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.
- Remove the six front halfshaft-to-differential bolts.
- 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.
- Slide the halfshaft outboard end into the hub, making sure that the splines engage.
- 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).
- Install the front disc brake caliper onto the rotor and anchor plate, then install and tighten the two caliper mounting bolts.
- 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.
- Install the hub nut onto the halfshaft and tighten the hub nut to 188-254 ft. lbs. (255-345 Nm).
- Install the hub nut retainer and a new cotter pin.
- Install the front wheels.
- Lower the vehicle to the ground.