How to Change the Front Axle Shafts on a 2002 Ford Expedition

The 2002 Ford Expedition was equipped with a 4.6-liter or 5.4-liter V-8 engine, four- or five-speed manual transmission, and two-, or four-wheel-drive. The front drive axle on the Expedition provides independent-front suspension by using axle shafts with CV-joints, similar to those used on front-wheel-drive vehicles. Replacing the front axle shafts is a labor-intensive process.

Instructions

Removal

1

Park the Expedition on a level, paved surface and set the parking brake. Remove the negative battery cable with a ratchet and socket. Remove the Cotter pin and lock ring from the end of the axle with pliers. Note how it is bent, and then discard the pin. Loosen the hub nut with a breaker bar and socket. Loosen the lug nuts. Raise the front of the Expedition with a jack and support it with jack stands. Remove the lug nuts and wheels.

2

Follow the axle shaft to where it connects to the flange on the axle tube -- on the passenger side -- or the differential housing on the driver side. Remove the six bolts from the flange with a ratchet and socket.

3

Remove the hub nut and washer with a ratchet and socket. Unbolt the brake caliper with ratchet and socket. Lift the caliper off the rotor and support it with a piece of wire tied to the frame. Disconnect the ABS sensor.

4

Unbolt the caliper bracket with a ratchet and socket and remove it. Slide the rotor from the hub. Unbolt the splash shield from the steering knuckle and remove it.

5

Remove the cotter pin from the tie rod end with the pliers. Note how the pin is bent. Loosen the castle nut most of the way off the tie rod end. Use a two-jaw puller to pop the tie rod end out of the steering knuckle. Remove the nut and pull the tie rod end from the knuckle.

6

Place a jack underneath the lower control arm. Raise the jack until it just begins to support the arm. Remove the Cotter pin from the lower ball joint. Loosen the castle nut most of the way but do not remove it. Use the two-jaw puller to pop the ball joint out of the knuckle. Repeat this process for the upper ball joint.

7

Use a three-jaw puller to draw the wheel hub and steering knuckle from the end of the axle shaft. Support the hub and knuckle with a piece of wire attached to the frame. Remove the drive axle from the vehicle.

Installation

8

Slide the axle in the vehicle and install the six flange bolts. Use a torque wrench and socket to torque the bolts to between 51 and 67 foot-pounds.

9

Slide the hub and knuckle onto the end of the axle. Install the upper ball joint and nut finger tight. Install the lower ball joint and nut finger tight. Use a torque wrench and socket to torque the upper ball joint nut to between 57 and 76 foot-pounds. You will need to make sure that the notch in the castle is aligned with the hole in the ball joint so you can install a new Cotter pin. Install a new pin and bend it in the same manner as the old one. All castle nuts must be aligned.

10

Torque the lower ball joint nut to between 83 and 112 foot-pounds. Install and bend a new Cotter pin.

11

Mount the tie rod and the steering knuckle and install the nut. Torque the nut to between 56 and 75 foot-pounds. Install and bend a new Cotter pin.

12

Install the hub washer and nut. Tighten the nut with a ratchet and socket as tight as you can get it. You will torque the nut to specification when the vehicle is on the ground. Install the splash shield and bolts.

13

Mount to the rotor onto the hub. Install the caliper bracket and bolts. Torque the bolts to 136 foot-pounds. Reconnect the ABS sensor. Mount the caliper onto the bracket, install the bolts and torque them to between 21 and 26 foot-pounds.

14

Install the wheel and lug nuts. Raise the front of the Expedition, remove the jack stands and lower it to the ground. Torque the lug nuts to between 83 and 112 foot-pounds. Torque the hub nut to between 188 and 254 foot-pounds. Install the lock and a new Cotter pin.