2002 F350 Front axle bearings

[Paul1orr]

HI All,
My nephew has an all stock 2002 F350 Dually that is a constant maintenance nightmare. One thing after the other since 40,000 miles. The latest thing is that while replacing the brakes and shocks up front for inspection, he noticed the axle seals were out and riding freely on the axle shafts behind the U-joints on both sides. He said both axle shafts easily moved up and down when he lifted them. The question is, what is involved in removing the axles to replace the bearings? Removing the hubs and hub bearings are no question and now is the time to replace those bearings but once the hubs are out of the way how do the axles come out? Do we need to remove C-clips in the diff or do the axles just pull out and are held in by the hubs?

I have no problem doing the work and had a trans shop in the 80’s with plenty of diff experience in the back and transfer cases but never had to mess with any front diffs. I haven’t looked to see what it is. Dana 60 or 70? I’m pretty sure the rear diff is a 70 from following the truck before. Y’all will know better than me. I just don’t want to step into a nightmare. Forewarned is forearmed.

BTW….the dealer wants $1500 just to do the hub bearings and he doesn’t have it. That’s how I got dragged into this mess. Any help and pointers will be appreciated.

Paul

[kanuck15]

no c clips. once the hubs and bearings are out they aught to slide out. Now you should have inner and outer seals. on those axles. they are worth replacing. But the biggest question is what do you mean riding freely? like with the all the parts assembled they still can wobble to the point of hitting the axle tube??

[Paul1orr]

I peaked under there when he told me that and saw the actual seal was completely out of the axle tube end and just riding out in space around the axle up close to the u-joint. He was able to just take one finger and push the seal toward the axle tube. The bearing had enough radial play to lift the axle up and down.....I didn't see that part, he told me....and I presume the movement is something like .020-.050 like the bearing rollers and races are shot from dirt water and rust.

[kanuck15]

that seems normal. the axle will have a little bit of movement to it for the u joints. sounds like it needs seals. regardless the axle has to come out anyways

[NoRalPh]

Yea, I'd say pretty normal too.....

Most everybodys seal is trashed there with that "O-ring" looking piece riding on the axle And there is actually nothing wrong with some play at the U-joint. I wouldn't panic.

IF you decide to replace things, keep in mind the parts are pretty expensive (that Knuckle Seal you see part of, is over $50 and to need to make a special tool to drive it in) and once you're in there you should go the whole route and replace the U-Joint, Knuckle Seal, Dust Seal, as well as the bearing hub because you don't want to have to go back in later and disturb that seal again.

[Paul1orr]

When I asked about the amount of play he said WAY more than .050....more like .150. Gonna do the whole shebang while we're in there.

Any way, thanks for the tips coz you just don't want to step into a pile of dog crap.

Paul

[NoRalPh]

Wait a min,,,, .150 ? Like a bit over 1/8th of an inch?

You're wasting your time, that is within acceptable tolerance. There is no support at the end of the tube and the axle really is OK with that much movement there.

[Paul1orr]

Yeah....over 1/8 of an inch. I can't believe there's no support there. What would keep the splines and such from getting torn up in the diff? And with U-joint velocities changing when it's engaged what keeps the axle from just banging around in the end of the tube? If that's true then that is all a piss poor design.....even Ford engineers aren't that dumb are they?

[Super Kaz]

Nice write up. Not everything will apply to your repair. I made the tool the way suggested in the article and it worked great.

Ford Super Duty Ball Joint Replacement Procedure | Superdutypsd.com

[NoRalPh]

Originally Posted by Paul1orr

Yeah....over 1/8 of an inch. I can't believe there's no support there. What would keep the splines and such from getting torn up in the diff? And with U-joint velocities changing when it's engaged what keeps the axle from just banging around in the end of the tube? If that's true then that is all a piss poor design.....even Ford engineers aren't that dumb are they?

I agree..... It doesn't, on the surface, make sense to me either! BUT, the fact is, it works Apparently doesn't need any support there.

btw... this is Not Fords design, but rather Dana who supplies the diff.