How to Replace Front U-Joints in a 94 F-150

The Ford F-150 was introduced in 1975. The 1994 F-150 was available in 16 different trim packages between the two-wheel- and four-wheel-drive models. The 1994 Ford F-150 four-wheel-drive models were equipped with the option of three different engines: 4.9-liter V-6, 5.0-liter V-8 and 5.8-liter V-8. The front drive shaft on the 1994 F-150 connects the transfer case to the front differential of the truck. Replacing the U-joints on this truck requires some prior mechanical knowledge and experience.

Instructions

1

Raise the front of the F-150 onto vehicle ramps. Place wheel chocks behind the rear tires of the truck. Lay beneath the driver's side of the car, and slide your body into position to access the front drive shaft. Draw a straight line from the drive shaft yoke to the front differential, using a white paint marker or crayon. Draw a straight line from the drive shaft yoke to the transfer case. These markings will be essential in the alignment of the drive shaft during installation. Don't use chalk for the marks as it smears and wears off easily.

2

Remove the U-bolt nuts and the U-bolts from the drive shaft axle flange, using a 3/8-inch drive ratchet, socket and extension. There are two nuts on each U-bolt. Place a jack stand beneath the front drive shaft, and pry the drive shaft loose with a small pry bar. Set the front of the drive shaft onto the jack stand.

3

Remove the U-bolt nuts from the transfer case, at the rear of the drive shaft. Use the ratchet, socket and extension to remove the nuts. Place your free hand beneath the rear of the drive shaft, while you are removing the second U-bolt. Do not let the drive shaft simply fall out of the transfer case. Lower the rear of the drive shaft to the ground gently once you have removed the U-bolts. Remove the drive shaft from beneath the truck completely.

4

Place the entire drive shaft onto a workbench, with one end of the drive shaft in a bench vise. Tighten the bench vise just so it is snug and holds the drive shaft from turning freely. Remove the U-joint retainer clips from the U-joint mounting holes in the drive shaft. Use needle-nose pliers to squeeze the clips, twist them and then pull them out. There are two clips attaching the U-joint to the drive shaft.

5

Insert a flat-head screw driver against the spider, or "+" shaped part of the U-joint, where the spider and the inner end of the rod bearing cap meet. Gently tap the screwdriver handle with a hammer to push the rod bearing cap off of the spider and out of the U-joint mounting hole in the drive shaft. Repeat this step to remove the second rod bearing cap from the other side of the drive shaft. Pull the U-joint spider free from the drive shaft, and remove it from your work area.

6

Remove two rod bearing caps from the new U-joint. Set the rod bearing caps so that the open end of the cap is facing straight upward. Do not turn the cap sideways or upside down, as the rod bearings will fall out or become askew, causing the bearing cap to become useless.

7

Install the exposed ends of the spider into position in the drive shaft. Place one rod bearing cap into the mounting hole of the drive shaft, while simultaneously pushing the spider into the bearing cap from the inside. Push the cap onto the spider as far as possible by hand. Insert the second bearing cap on the opposite side of the drive shaft, while still holding the spider in place.

8

Mount a large C-clamp against the bearing caps. Tighten the C-clamp to push one bearing cap onto the spider. Turn the C-clamp around and repeat this process for the second rod bearing cap. Install new U-joint retainer clips onto the drive shaft, using needle-nose pliers. Squeeze the clips inward, insert them into the recesses provided in the drive shaft holes, then release the clips. Use a flat-head screwdriver to snap the clips in place if needed.

9

Remove the drive shaft from the bench vise, and flip it around end-to-end. Repeat Steps 4 through 8 to complete the U-joint replacement of the second end of the drive shaft.

10

Lay the drive shaft beneath the truck. Align the drive shaft up beneath the transfer case and the front differential. Place the front end of the drive shaft onto a jack stand. Install the rear end of the drive shaft against the transfer case, making sure the marks between the shaft and case line up. Install the U-bolts around the U-joints and onto the transfer case. Tighten the U-bolt nuts to 180 inch-pounds of torque, using a 3/8-inch-drive torque wrench, socket and extension.

11

Lift the front of the drive shaft up to the differential. Make sure your markings on the shaft and differential align with one another. Install the U-bolt nuts around the front U-joints and onto the differential. Tighten the U-bolt nuts to 180 inch-pounds of torque with the torque wrench, socket and extension.