How to Change a Front Axle Universal Joint on a 1997 Ford F-250

The 1997 Ford F-250 3/4-ton truck was available with four-wheel drive. A transfer case with high- and low-range can be engaged to transfer power to the front axle. A two-piece driveshaft with u-joints at each end connects the output flange on the transfer case with the pinion flange on the axle. U-joints can be a little tricky to replace but should not be beyond the capabilities of the DIY mechanic.

Instructions

Removal

1

Park the F-250 on a level, paved surface and set the parking brake. Raise the front of the F-250 with a jack and support with jack stands.

2

Remove the nuts from the driveshaft skid plate with a ratchet and socket, and remove the plate. There are three nuts.

3

Paint a mark on the transfer case flange, across the driveshaft yoke and driveshaft with white marking paint. Repeat this process for the pinion flange and front of the driveshaft. You will line up these marks when you reinstall the driveshaft. Failure to install the driveshaft in its original position can result in vibration in the driveshaft.

4

Remove the four bolts that hold the front and rear of the driveshaft to the pinion and transfer case flanges, using a ratchet and socket. Remove the driveshaft.

5

Remove the snap-rings from the ends of the yokes, using snap-ring pliers. They fit in grooves in the yokes, on top of the u-joint bearing caps.

6

Choose a socket that is just small enough to fit in the yoke and make contact with the bearing cap. Choose another socket that is just large enough for the bearing cap to fit in. You will use these sockets to press out the caps. In the alternative, you can take the driveshaft to a shop and have the u-joints pressed in for a small fee.

7

Lay the driveshaft on a workbench. Mount the driveshaft in a vise with the small socket fitted inside the yoke, against the bearing cap, and the large socket on top of it. Close the vice to push the small socket into the yoke, thereby pushing the other bearing cap into the larger socket. Push the small socket in about 3/8 of an inch and stop.

8

Remove the driveshaft from the vise. Grab the exposed bearing cap with a pair of pliers and twist it out of the yoke. Lift the u-joint body out of the cap and angle it out of the yoke.

9

Put the driveshaft back in the vise, using only the small socket to push the other bearing cap the rest of the way through the yoke. Repeat this process for the other two bearing caps.

Installation

10

Remove a bearing cap from a new u-joint. Be careful not to disturb the needle bearings that line the cap. Mount the cap in the driveshaft and place them in the vice. Close the vice to push the cap in about 3/8 inch.

11

Remove the opposite bearing cap from the new u-joint. Angle the body of the u-joint into the driveshaft and down into the cap. Mount the other cap on the driveshaft, place the driveshaft in the vice, and push the caps together while centering the u-joint body so it slides between the needle bearings in both caps.

12

Use the small socket to push the caps in just past the snap-ring grooves. If the caps will not go in or the u-joint is tight, you have disturbed the needle bearings and will have to take it apart, realign the bearings and start over.

13

Repeat this process for the yoke, making sure to keep the marks aligned. Repeat this process for the other end of the driveshaft.

14

Install the snap rings. If they do not quite want to go into the grooves, strike the driveshaft with a brass hammer. They should snap into place. If they still do not want to go in, place a flat-head screwdriver against the side of the snap-ring and tap it with a hammer.

15

Mount the driveshaft in the F-250, line up the marks, and install the bolts at the front and rear of the driveshaft. Use a torque wrench to torque the bolts to between 70 and 95 foot-pounds on the front of the driveshaft and between 65 and 88 foot-pounds on the rear of the driveshaft.

16

Install the skid-plate and nuts. Tighten the nuts to between 16 and 20 foot-pounds, using a torque wrench and socket. Raise the front of the F-250, remove the jack stands and lower it to the ground.