2004 Front Axle Removal - Ford Powerstroke Diesel Forum
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Old 05-22-2012, 08:09 PM
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2004 Front Axle Removal

Doing ball joints now. Done many in the past, but first time on the 04 Excursion with vacuum and ABS. Got the wheel bearing assembly out no problem. Now the axle should just tap out...right?

I have tapped, pried and pounded for 2 hours and while the axle is loose, it appears to have a seal in the knuckel thats really hanging it up. If I didn't know better, I'd say the dust ring on the kunckel is larger diameter than the hole it needs to come out of. Always nervous about bringing out the big hammer, but is that what I need to do to get these out?
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Old 05-22-2012, 08:15 PM
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Just keep prying. Same problem with mine last year. Get some one to pull on the shaft as you pry.
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Old 05-23-2012, 02:36 PM
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Quote:
Originally Posted by 2004f2501 View Post
Get some one to pull on the shaft as you pry.
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Old 10-24-2012, 05:45 PM
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Did you ever figure out the problem. I am having the same problem now and cant find anything to help me out.
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Old 10-24-2012, 06:00 PM
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This can be tricky. Some of these seals are really stuck, especially 05+ knuckles.

The early small hub seals can usually be pryed loose. The 05+ I always knock them out with an air chisel and a blunt round bit.
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Old 10-25-2012, 06:20 AM
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I did...its really is one of those "add more force" kinda things. But I found that impact force (hammer) did not work as the rubber seal just absorbes the impact. Hard to describe without a picture, but basically I used the prybar to push the axle as lateral as possible...top, then bottom, as the seal will tend to kinda wedge itself tighter of you don't keep it parallel with the bore. So there's a steel dust ring around the axle, then a foam boot, then the rubber seal. That foam boot kinda hangs up movement of the axle. I used a screwdriver to push that boot into the bore little by little. Once the foam ring is past the edge of the bore, it all moves out pretty easy.

Hope that helps!
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Old 10-25-2012, 06:38 AM
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air chisel is a snap if you aren't trying to save that Hub seal

you may want to see if the 04 can take the updated dust seal that always falls off the axle
the new style goes in the axle tube
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Old 10-25-2012, 07:53 PM
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yes i did. just need to pry it out from behind. some have used air chisles. just keep trying and good luck
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