2001 4x4 Hub Emergency

[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...

[shawnb99]

i would venture to say that if you are refering to washers on the stock assembley, and now with an aftermarket unit you are having problems that not all the washers are needed. if there is a machining difference and the washers are to thick to compress to install the snap ring, i would bet it is intended not to use all.

[jse51599]

Which seal did you install? Maybe you installed the seal too far back, which in turn moved the outer shaft inwards towards the differential just enough to not allow enough room for the third washer? I recently did new hubs, but not dust seals, and I was able to re-install all the washers..... Only thing I can think to check is the difference between the two sides where the dust seals seat in the knuckle....

[Ronney]

I install both seals, I used the proper tool to ensure correct alignment. I'll hammer at it today. It's just an RCH off. any ideas of what will happen is I run it with only two washers?

[Robs97z28]

I believe the axle stub shaft got pushed in. you just need to pull the axle out a little and the 3 washers in place. this is what happen to me when I replaced my ball joints.

[Ronney]

I pulled it all apart and you were right I pushed it in to far. I took it all apart because the parts I bought online through this site (Super Duty F250 F350 4x4 Complete Ball Joint Kit 1999 2004), the lower ball joints were 1/2" to tall. I was pissed and it cost me way more because I stranded. Venting....

Today my gear oil started coming out of the right axle????

When I pulled the right side off the thrust washer was not even there...

I'm up and running just tired and frustrated