Axle Shafts - Front

2003 Ford Pickup F150
2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)
2000-03 DRIVE AXLES
Axle Shafts - Front - F150 Pickup (4WD)
DESCRIPTION & OPERATION
CAUTION: DO NOT over angle the CV joints. Damage will occur to an assembled
inboard CV joint if it is over-plunged outward from the joint housing. Never
use a hammer to remove or install the axle shafts. Never use the axle shaft
assembly as a lever to position other components. Always support the
free end of the axle shaft. DO NOT allow the CV joint boots to contact
sharp edges or hot exhaust components.
CAUTION: Handle the axle shaft only by the interconnecting shaft to avoid pull-apart
and potential damage to the CV joints. DO NOT drop assembled axle
shafts. The impact will cut the CV joint boots from the inside without
evidence of external damage. Keep CV joints clean and maintain correct
grease refill when installing NEW axle shaft components. DO NOT remove
the outer CV joint by pulling on the interconnecting shaft. Inspect all
machined surfaces and splines for damage.
Inboard and outboard Constant Velocity (CV) joints connect to a splined shaft. Axle shaft bearing retainer
circlips retain the CV joints to the splined shaft. On the right side, a axle shaft bearing retainer circlip retains the
splined inboard CV joint to the differential side gear. Install a NEW circlip and stop ring, every time you
remove the axle shaft from the vehicle. A axle shaft hub nut secures the splined outboard CV joint to the wheel
hub. The lubed-for-life CV joints use special CV joint grease. They require no periodic lubrication.
Handle all axle shaft components carefully during removal and installation and during various component
disassembly and assembly procedures. For exploded view of axle shafts, see Fig. 1 . New axle shaft
components are available as follows:
z A repair kit includes the boots, clamps, snap ring, retaining ring, and grease.
z A new inboard CV joint (plunge type).
z A new outboard CV joint and interconnecting shaft assembly includes the outboard front wheel axle shaft
joint (fixed type), boot, clamps, and the front wheel excluder seal (assembled on the joint).
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11:18:24 AM Page 1 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Exploded View Of Axle Shaft & CV Joint

Courtesy of FORD MOTOR CO.
LUBRICATION
Front hub bearings are a cartridge design and require no scheduled maintenance. CV joint assemblies, use Ford
High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent.
TROUBLE SHOOTING
NOTE: New Constant Velocity (CV) joints must not be installed unless disassembly and
inspection reveals unusual wear.
CLICKING, POPPING OR GRINDING NOISES WHILE TURNING
Inadequate Or Contaminated Lubricant In Inner/Outer Axle Shaft CV Joint
Inspect the boots for indentations ("dimples") in the boot convolutions. Indentations must be removed. Inspect
the boots for evidence of cracks, tears, or splits. Inspect the underbody for any indication of grease splatter near
the boots outboard and inboard locations. This is an indication of boot/clamp damage. Inspect, clean and
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March-02-08 11:18:24 AM Page 2 2005 Mitchell Repair Information Company, LLC.
lubricate inner/outer axle shaft CV joint as necessary.
Another Component Contacting Axle Shaft Assembly
Inspect and repair as necessary.
Brake Components
Inspect, and repair as necessary. See appropriate article in BRAKES.
Wheel Bearings, Suspension Or Steering Components
Inspect and repair wheel bearings, suspension or steering components as necessary. See appropriate FRONT
article in SUSPENSION.
SHUDDER VIBRATION DURING ACCELERATION
High CV Joint Operating Angles Caused By Incorrect Ride Height
Check the ride height, and verify the spring rate. See appropriate SPECIFICATIONS & PROCEDURES article
under WHEEL ALIGNMENT in SUSPENSION. Repair appropriate suspension component(s) as necessary.
See appropriate FRONT article in SUSPENSION.
Front Suspension Components
Check for worn suspension bushings and component damage. Repair appropriate suspension component(s) as
necessary. See appropriate FRONT article in SUSPENSION.
Excessively Worn Or Damaged Inboard Or Outboard CV Joint
Inspect and install NEW CV joint(s) as necessary. See AXLE SHAFTS under REMOVAL &
INSTALLATION.
VIBRATION AT SPEEDS GREATER THAN 35 MPH
Out Of Balance Or Out-Of-Round Tires
Balance the wheel and tire assemblies or INSTALL new wheels or tires as necessary
Incorrectly Seated Outboard CV Joint In Front Wheel Hub
Repair or install NEW outboard CV joint or front wheel hub component(s) as necessary. See AXLE SHAFTS
under REMOVAL & INSTALLATION.
Lateral & Radial Tire & Wheel Runout
Repair or install NEW tires or wheels as necessary.
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Worn CV Joint
Install NEW axle shaft. See AXLE SHAFTS under REMOVAL & INSTALLATION.
REMOVAL & INSTALLATION

AXLE SHAFTS
NOTE: Numbers in parentheses refer to numbers in illustration. This procedure applies

to both the left and right side axle shaft assemblies.
Removal & Installation
1. Raise and support the vehicle.

2. Remove the wheel and tire assembly.
3. Remove and discard the cotter pin (1). Remove the retainer (2). Remove the axle shaft hub nut (3). See
Fig. 2 .
CAUTION: Do not allow the front disc brake caliper to hang from the brake hose.
Provide a suitable support.
4. Remove the bolts (1). Lift the caliper (2) from the anchor plate and position it aside. See Fig. 3 .
5. Remove and discard the cotter pin (1). See Fig. 4 . Remove the upper ball joint nut (2).
6. Using Steering Arm Remover (211-003, T64P-3590-F), separate the front wheel knuckle from the front
suspension upper arm. See Fig. 5 .
7. Remove the six axle shaft-to-axle bolts.
CAUTION: Do not damage the hub seal.
8. Separate the axle shaft from the axle and the hub, and remove the assembly from the vehicle. To install,
reverse the removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .
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Fig. 2: Removing Axle Shaft Hub Nut

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Fig. 3: Identifying Caliper bolts

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Fig. 4: Identifying Upper Ball Joint Cotter Pin & Nut

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Fig. 5: Separating Front Wheel Knuckle From Front Suspension Upper Arm
OVERHAUL
AXLE SHAFTS
Disassembly (Inboard Joint)
1. Remove the axle shaft from the vehicle. See AXLE SHAFTS under REMOVAL & INSTALLATION.
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CAUTION: Do not damage the boot.
2. Remove the boot clamps. See Fig. 6 . Separate the boot from the inboard CV joint housing. See Fig. 7 .
Remove the retaining ring. See Fig. 8 .
3. Remove the inboard CV joint housing. See Fig. 9 . Index-mark the inner race and ball cage. See Fig. 10 .
4. Remove the six balls. See Fig. 11 . Remove the snap ring. See Fig. 12 . Remove the inner race and the
ball cage.
5. Remove the inner race and the ball cage. See Fig. 13 .
NOTE: This step is for replacing the outboard CV joint boot.
6. Remove the outboard boot clamps. Remove the outboard boot. Check the grease for contamination. See
Fig. 14 . If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV
joint and interconnecting shaft assembly if worn/damaged
Reassembly
1. If you are not replacing the outer CV joint boot, go to step 4 . If you are replacing outer CV joint boot,
position the outboard boot on the shaft. Pack the outboard CV joint with 5.82 ounces (165 grams) of
grease. Use High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent provided in the
boot kit.
2. Spread any remaining grease from the kit evenly inside the boot. Clean the boot mounting surface. See
Fig. 15 . Seat the boot in the joint boot groove. Position the boot clamps.
NOTE: Tighten the through-bolt until the tool is in the closed position.
3. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig. 16 .
4. Position the inboard boot clamp on the shaft. Position the inboard boot on the shaft.
5. Position the ball cage on the shaft with the tapered end facing the boot. See Fig. 17 . Position the inner
race on the shaft with the counterbored end facing the boot. Align the index marks. See Fig. 10 . Install
the snap ring. See Fig. 12 .
6. Lubricate and position the six balls. See Fig. 11 . Use High Temp Constant Velocity Joint Grease (E43Z-
19590-A), or equivalent provided in the boot kit.
7. Fill the inboard CV joint housing with 8.29 ounces (235 grams) of grease. Use High Temp Constant
Velocity Joint Grease (E43Z-19590-A), or equivalent provided in the boot kit.
8. Position the boot clamp on the inboard CV joint housing. See Fig. 18 . Position the inboard CV joint
housing on the ball and race assembly. Install the retaining ring. See Fig. 19 .
9. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove. Set the axle
shaft assembled length to specification. See Fig. 20 . See AXLE SHAFT ASSEMBLED LENGTH
table.
CAUTION: Do not damage the boot.

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10. Insert a dull screwdriver blade under the boot to release the pressure. See Fig. 21 .
NOTE: Tighten the through-bolt until the tool is in the closed position.
11. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig. 22 . Install the axle
shaft in the vehicle. See AXLE SHAFTS under REMOVAL & INSTALLATION.
AXLE SHAFT ASSEMBLED LENGTH

Application In. (mm)
Left & Right Side 16.43 (417.3)
Fig. 6: Locating CV Boot Clamps

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Fig. 7: Removing/Installing Inner CV Joint Boot

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Fig. 8: Removing Inboard CV Joint Retaining Ring

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Fig. 9: Removing Inboard CV Joint Housing

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Fig. 10: Index-Marking Inner Race & Ball Cage

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Fig. 11: Removing/Installing Inner CV Joint Balls

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Fig. 12: Removing/Installing Inner CV Joint Snap Ring

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Fig. 13: Removing Inner CV Joint Inner Race & Ball Cage
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Fig. 14: Checking Grease For Contamination

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Fig. 15: Installing Outer CV Joint Boot

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Fig. 16: Installing Outer CV Joint Boot Clamps

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Fig. 17: Installing Inner CV Joint Ball Cage

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Fig. 18: Installing Ball & Race Assembly Into Inboard CV Joint Housing
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Fig. 19: Installing Retaining Ring

Fig. 20: Measuring Axle Shaft Assembled Length

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Fig. 21: Releasing Pressure from Inboard CV Joint Boot

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Fig. 22: Installing Inboard CV Joint Boot Clamps

Disassembly & Reassembly (Outboard Joint)
The outboard CV joint is part of the axle shaft and can not be serviced separately. To replace the outer CV joint
boot, see DISASSEMBLY (INBOARD JOINT) .
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Axle Shaft Hub Nut 221 (300)
Axle Shaft-To-Axle Bolts 60 (82)
Front Disc Brake Caliper-To-Anchor Plate Bolts 24 (32)
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Steering Knuckle-To-Suspension Upper Arm 66 (90)

Wheel Lug Nuts 100 (135)
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Axle Shafts - Front

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Axle Shafts - Front

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2003 Ford Pickup F150

2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)

2000-03 DRIVE AXLES

Axle Shafts - Front - F150 Pickup (4WD)

DESCRIPTION & OPERATION

Fig. 1: Exploded View Of Axle Shaft & CV Joint

CLICKING, POPPING OR GRINDING NOISES WHILE TURNING

Inadequate Or Contaminated Lubricant In Inner/Outer Axle Shaft CV Joint

lubricate inner/outer axle shaft CV joint as necessary.

Another Component Contacting Axle Shaft Assembly

Inspect and repair as necessary.

Inspect, and repair as necessary. See appropriate article in BRAKES.

Wheel Bearings, Suspension Or Steering Components

SHUDDER VIBRATION DURING ACCELERATION

High CV Joint Operating Angles Caused By Incorrect Ride Height

Front Suspension Components

Excessively Worn Or Damaged Inboard Or Outboard CV Joint

VIBRATION AT SPEEDS GREATER THAN 35 MPH

Out Of Balance Or Out-Of-Round Tires

Incorrectly Seated Outboard CV Joint In Front Wheel Hub

Lateral & Radial Tire & Wheel Runout

Repair or install NEW tires or wheels as necessary.

REMOVAL & INSTALLATION

NOTE: Numbers in parentheses refer to numbers in illustration. This procedure applies

Removal & Installation

1. Raise and support the vehicle.

CAUTION: Do not damage the hub seal.

Fig. 2: Removing Axle Shaft Hub Nut

Fig. 3: Identifying Caliper bolts

Fig. 4: Identifying Upper Ball Joint Cotter Pin & Nut

Disassembly (Inboard Joint)

CAUTION: Do not damage the boot.

NOTE: This step is for replacing the outboard CV joint boot.

CAUTION: Do not damage the boot.

AXLE SHAFT ASSEMBLED LENGTH

Fig. 6: Locating CV Boot Clamps

Fig. 7: Removing/Installing Inner CV Joint Boot

Fig. 8: Removing Inboard CV Joint Retaining Ring

Fig. 9: Removing Inboard CV Joint Housing

Fig. 10: Index-Marking Inner Race & Ball Cage

Fig. 11: Removing/Installing Inner CV Joint Balls

Fig. 12: Removing/Installing Inner CV Joint Snap Ring

Fig. 14: Checking Grease For Contamination

Fig. 15: Installing Outer CV Joint Boot

Fig. 16: Installing Outer CV Joint Boot Clamps

Fig. 17: Installing Inner CV Joint Ball Cage

Fig. 19: Installing Retaining Ring

Fig. 20: Measuring Axle Shaft Assembled Length

Fig. 21: Releasing Pressure from Inboard CV Joint Boot

Fig. 22: Installing Inboard CV Joint Boot Clamps

Disassembly & Reassembly (Outboard Joint)

Steering Knuckle-To-Suspension Upper Arm 66 (90)

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