Need Help on 01 Hub Assembly

[Ronney]

I was replacing the ball joints on my 2001 F250 Platinum Edition today. I was also replacing the hub assembly while I'm into the project. As I was reassembling it I could NOT get all three thrust washers back in with the snap ring. The only way was to remove a washer then the snap ring fit snuggly.

I bought Timken hub assemblies, I even purchased the tool to install the seal for the axle. I can't figure it out. I have it over at Lackland Ai Force Base sitting in a stall waiting for me to finish it up tomorrow and then attempt/finish the passenger side.

Any clue on what I may have done that would not allow all three washers to fit back on? This is emergency for me as I need the truck working by Saturday night.

A secondary question, will any damage occur if I can't fix this issue? I don't use 4x4 but once a year. I love my truck and like doing things the right way...

[NoRalPh]

Are you sure you drove the Knuckle Seal in far enough?

Look through this link, it has good pics of the reassembly - > Welcome to guzzle's 4x4 Needle Bearing Maintenance Web Page

Here's another good link showing the seal -> Ford Super Duty Ball Joint Replacement Procedure | Superdutypsd.com

[Ronney]

I took it all apart again. I had to, the lower Ball joint I ordered was 1/2" to tall. It struck the u-joint. Thank God I dropped a part and looked up and saw it. Who would think to check the parts by comparing them side by side when you order from reputable people.

Its all together, however, I have gear oil coming out of the right axle. The right side was slightly lower than the left so that was bit of an issue when it was on the lift. THose dust seals are pieces of crap.

I was told that the inner seal near the pumpkin is the real seal. Do you think I could have damaged it reinstalling?

P.S. Thanks for the links and advice.