Page 1 of 5 Section 05-03A: Axle, Front Drive, Dana Models 44 and 50 1996 Bronco/F-Series Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/19/2000 Spindle, RH and LH Shaft and Joint Assembly SPECIAL SERVICE TOOL(S) REQUIRED Description Impact Slide Hammer Bearing Cup Puller Tool Number T50T-100-A T77F-1102-A Spindle Bearing Replacer T80T-4000-R Spindle Bearing Replacer T80T-4000-S Driver Handle Driver Handle Shaft Seal Replacer Shaft Seal Replacer Keystone Clamp Pliers T80T-4000-W T92T-4000-A T95T-3132-E T95T-3132-C T83T-3132-A1 T95T-3132-A T95T-3132-B T63P-9171-A Removal 1. Raise the vehicle and install safety stands. 2. Remove the wheels (1007) and tires. Refer to Section 04-04. 3. On vehicles equipped with four-wheel anti-lock brakes, remove the front brake anti-lock sensor (2C204) from the steering knuckle. Refer to Section 06-09B. 4. CAUTION: After removal, the disc brake caliper (2B120) must be wired to the frame or otherwise supported to prevent suspending the disc brake caliper by the flexible hose. If securing the disc brake caliper is not practical, disconnect the brake hose from the disc brake caliper. Plug the hose end to prevent fluid loss and entry of air into the system. Upon installation of the disc brake caliper, bleed the brake system as described in Section 06-00. Remove the disc brake caliper. Refer to Section 06-03. Securely wire the disc brake caliper to the frame. Spindle and LH Shaft and Joint Installation, Typical 1 3B403 Axle Arm (LH) 2 3219 Shaft 3 3C132 Axle Shaft Rolling Diaphragm Seal (RDS) 4 3249 Front Axle Shaft Universal Joint 5 87747-S2 Filler Plug 6 3A049 Nut 7 72035-S Pin 8 3049 Front Suspension Upper Ball Joint 9 3A050 Nut 10 3K050 Snap Ring

Page 2 of 5 11 3050 Front Suspension Lower Ball Joint 12 3130 Steering Knuckle Assembly 13 2K004 Front Disc Brake Rotor Shield 14 3299 Integral Spacer/Seal 15 3123 Caged Needle Bearing 16 3105 Front Wheel Spindle 17 35704 Nut 18 3254 Spindle Rolling Diaphragm Seal (RDS) (F-150 and Bronco Only) 19 1190 Wheel Hub Grease Seal 20 4221 Differential Bearing 21 4222 Differential Bearing Cup 22 1102 Front Disc Brake Hub and Rotor 23 (Part of 1102) Hub A Tighten to 136 Nm (100 Lb-Ft) B Tighten to 123-149 Nm (91-110 Lb-Ft) C Tighten to 47 Nm (35 Lb-Ft) for Model 44 or 68-81 Nm (50-60 Lb-Ft) for Model 50. RH Shaft and Joint Assembly Installation, Typical 1 1175 Rolling Diaphragm Seal 2 3B400 Camber Adjuster 3 3B402 Right Support Arm 4 3B478 Keystone Clamp 5 3A466 Slip-Yoke and Stub Shaft 6 3B403 Left Axle Arm 7 3A429 Rubber Boot 8 3219 Right Shaft and Joint 5. Remove hub locks, wheel bearings, and locknuts. Refer to Section 05-03C. 6. Remove the front disc brake hub and rotor (1102) and front wheel bearing (1216) from the front wheel spindle (3105). 7. Inspect the outer spindle hub rolling diaphragm seal for F-150 and Bronco only. If necessary, pry off using a screwdriver. 8. NOTE: Relieve the suction between the axle shaft rolling diaphragm seal (RDS) and the front wheel spindle by gently lifting the seal lip away from the back of the front wheel spindle which will allow the front wheel spindle to slip off the axle shaft. Remove the nuts retaining the front wheel spindle to the steering knuckle. Tap the front wheel spindle with a nylon or rawhide hammer to jar the front wheel spindle from the knuckle. Remove the front disc brake rotor shield (2K004). 9. On the left side of the vehicle remove the shaft and joint assembly by pulling the assembly out of the carrier.

Page 3 of 5 10. On the right side of the carrier, remove and discard the keystone clamp from the shaft and joint assembly and the stub shaft. 11. NOTE: Since the splines on the shaft are not phased, the shaft and joint assembly and slip-yoke must be marked to maintain U-joint phasing during assembly. Slide the rubber boot onto the stub shaft. Mark the shaft and slip-yoke to maintain U-joint phasing during assembly. Pull the shaft and joint assembly from the splines of the stub shaft. 1 3219 Shaft and Joint Assembly 2 3B478 Keystone Clamp 3 3A429 Boot 4 3220 Shaft and Joint Assembly 12. Remove rolling diaphragm seal from axle shaft. 13. Place the front wheel spindle in a vise on the second step of the front wheel spindle. Wrap a shop towel around the front wheel spindle or use a brass-jawed vise to protect the front wheel spindle. 14. Remove the integral spacer/seal and needle bearing from the front wheel spindle with Impact Slide Hammer T50T-100-A and Bearing Cup Puller T77F-1102-A. 15. Inspect the sealing surfaces of the front wheel spindle for severely corroded, pitted, worn or galled sealing surfaces. Replace front wheel spindle if damaged. 16. Inspect the outer shaft of the axle shaft assembly for corroded, pitted, worn or galled surfaces in the inner oil seal or needle bearing areas. If damaged, replace the outer shaft. Repair axle shaft U-joint. Refer to Section 05-01. Installation 1. Clean all dirt and grease from the bearing bore of the front wheel spindle. Bearing bores must be free from nicks and burrs. 2. NOTE: Replacement spindle bearings are shipped with a corrosion-preventive gel. This is not a lubricant. The bearing must be cleaned and replaced with the specified

Page 4 of 5 lubricant. Install a new needle bearing with writing facing outward in the bore of the front wheel spindle with Spindle Bearing Replacer T80T-4000-R on the Dana 50, or T80T-4000-S for the Dana 44 and Driver Handle T80T-4000-W. Lubricate the bearing with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. 3. Install a new integral spacer needle bearing seal. Pack spindle bearing with grease (see Step 2). Install seal with Seal Replacer T92T-4000-A and Driver Handle T80T-4000-W for Model 50. For Model 44, use Driver Handle T80T-4000-W and T95T-3132-E. 4. For F-150 and Bronco only, install outer spindle hub rolling diaphragm seal. Seat the rolling diaphragm seal by lightly tapping on the inner sheet metal lip of the seal with Spindle Seal Replacer T95T-3132C, Driver Handle T83T-3132-A1, and a hammer to make sure it is sealed squarely. Installation of Spindle Rolling Diaphragm Seal F-150 and Bronco Only 5. Install the rolling diaphragm seal on the axle shaft. The lip of the seal should face toward the front wheel spindle. Seat the rolling diaphragm seal by lightly tapping on the inner sheet metal lip of the seal with a Shaft Seal Replacer T95T-3132-A for F-150 and Bronco or T95T-3132-B for F-250, Driver Handle T83T-3132-A1, and a hammer to make sure it is seated fully and squarely. 6. Lightly coat the lips of the axle shaft rolling diaphragm seal (RDS) and the mating surface of the front wheel spindle with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.

Page 5 of 5 7. NOTE: Since the splines on the shaft are not phased, the shaft and joint assembly and slip-yoke must be marked to maintain U-joint phasing during assembly. On the right side of the carrier, install the rubber boot and new keystone clamps on the stub shaft slip-yoke. 8. Align the mark (made during removal) in the slip-yoke barrel with the mark on the shaft and joint assembly. 9. Slide the right shaft and joint assembly through the knuckle and into the slip-yoke making sure the splines are fully engaged. 10. Slide the boot over the assembly and crimp the keystone clamp using Keystone Clamp Pliers T63P-9171-A. 11. On the left side of the carrier slide the shaft and joint through the knuckle and engage the splines on the shaft in the carrier. 12. NOTE: Make sure the grease seal lip totally encircles the front wheel spindle. NOTE: Lightly coat the splindle RDS seal lip and its mating surface on the hub and rotor with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. Install the front disc brake rotor shield and front wheel spindle onto the steering knuckle. Install and tighten the nuts of the front wheel spindle to 68-81 Nm (50-60 lb-ft) for Model 50 axle or 47 Nm (35 lb-ft) for Model 44 axle. 13. CAUTION: Any dents or nicks in the can of the wheel bearing seal can prevent proper sealing. Install the front disc brake hub and rotor on the front wheel spindle. Install the outer wheel bearing into the cup. Refer to Section 05-03C. 14. Install the wheel bearing, locknut, front wheel outer bearing retainer washer (1195), snap ring and locking hubs per Section 05-03C. 15. Install the disc brake caliper. Refer to Section 06-03. 16. On vehicles equipped with four-wheel anti-lock brakes, install the front brake anti-lock sensor on the steering knuckle. Refer to Section 06-09B. 17. Fill front axle lubricant. 18. Remove the safety stands and lower the vehicle.