Suspension: Service and Repair

Axle - F-250, F-350, Excursion

Special Tool(s):

Special Tool(s)

Removal

CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during re-assembly to ensure proper retention of these parts.

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the front disc brake caliper, front disc brake hub and rotor and front disc brake rotor shield.





4. If equipped, remove the front disc brake ABS sensor retainer bolt and the ABS sensor harness bracket bolt from the front wheel spindle. Position the ABS sensor out of the way.





5. Remove the cotter pin and the castellated nut from the tie rod end. Discard the cotter pin.





6. Using the Pitman Arm Puller, remove the tie rod end.





7. Remove the cotter pin and the lower ball joint castellated nut. Discard the cotter pin.





8. Remove the pinch bolt and the camber adjuster from the upper ball joint.





9. CAUTION: To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints.

Remove the front wheel spindle.
1. Strike the lower end of the axle to loosen the ball joint.
2. Remove the front wheel spindle.
10. Using a suitable jack, support the front axle.
11. Remove the front coil spring.





12. Remove the lower spring insulator.





13. Remove the lower spring seat.





14. Remove the radius arm-to-axle bolt and nut.





15. Remove the radius arm-to-frame bracket pivot bolt and nut. Remove the radius arm.





16. NOTE: In order to obtain clearance for the pivot bolt removal when servicing the RH front axle, it may be necessary to raise the side of the vehicle to relieve the weight on the suspension.

Remove the pivot nut and bolt, and remove the axle.

Installation
1. Inspect the pivot bushing for wear or damage. Replace as necessary.





2. Position the front axle into the pivot bracket and install a new pivot bolt and nut hand-tight.
3. Inspect the radius arm pivot bushing for wear or damage. Replace as necessary.





4. Install a new radius arm-to-axle bolt and nut hand-tight.





5. Install a new radius arm-to-frame bracket pivot bolt and nut. Tighten to specification.





6. Tighten the radius arm-to-axle bolt and nut to specification.





7. Install the lower spring seat.





8. Install the lower spring insulator.
9. Install the front coil spring.





10. NOTE: Tighten the ball joint nut further, if necessary, in order to insert the new cotter pin.

Using new fasteners, install the front wheel spindle in the front axle.
1. Position the front wheel spindle in the front axle.
2. Install the ball joint nut and tighten to specification.
3. Install the new cotter pin.





11. Install the camber adjuster and a new pinch bolt.
12. Install the front disc brake rotor shield, front disc brake hub and rotor and the front disc brake caliper.





13. If equipped, install the front disc brake ABS sensor, retainer bolt and the ABS sensor harness bracket bolt.





14. Install the tie rod end in the front wheel spindle using a new nut and a new cotter pin.
15. Install the tire and wheel assembly.





16. Lower the vehicle and with the vehicle weight on the suspension, tighten the axle pivot bolt and nut to specification.
17. Perform front end alignment.