Section 05-02E: Wheel Hubs and Bearings, Rear, Dana Full-Floating Axle | 1996 F-Super Duty and Motorhome Chassis Vehicles Workshop Manual |
NOTE: For disassembly and assembly procedures for rear hubs (1109) and rear wheel bearings on Ford full-floating rear axles (4001), refer to Section 05-02B.
WARNING: DO NOT ATTEMPT TO USE OLDER VEHICLE LUG NUTS (CONE-SHAPED, ONE-PIECE) TO REPLACE THE INTEGRAL TWO-PIECE SWIVELING LUG NUTS (1012). PRE-1985 LUG NUTS CAN COME LOOSE DURING VEHICLE OPERATION. DO NOT ATTEMPT TO USE OLDER VEHICLE WHEELS, WHICH HAVE CONE-SHAPED LUG NUT SEATS, ON THIS VEHICLE. DO NOT ATTEMPT TO USE THE NEW DESIGN WHEELS AND LUG NUTS ON PAST MODEL WHEEL HUBS AS THIS CAN LEAD TO DAMAGE TO THE WHEEL MOUNTING SYSTEM AND COULD RESULT IN WHEELS COMING LOOSE DURING OPERATION.
| Description | Tool Number |
|---|---|
| Hub Locknut Wrench | T88T-4252-A |
| Inner Bearing Cup Remover | T88T-1175-B |
| Driver Handle | T80T-4000-W |
| Outer Bearing Cup Remover | T88T-1175-A |
| Bearing Cup Replacer | T88T-1175-C |
| Threaded Drawbar | T75T-1176-A |
Disassembly
Set the parking brake and loosen the axle shaft attaching bolts and lug nuts.
Raise the rear wheels (1007) off the floor and place safety stands under the rear axle housing (4010).
Release the parking brake.
Using a heavy-duty wheel dolly such as Rotunda Wheel Dolly 014-00030 or equivalent, raise the wheel to the point that all weight is removed from the wheel bearings. Remove the wheel.
Place a drain pan under the rear hub. Remove the axle shaft attaching bolts and discard them.
Remove the axle shaft (4234) and discard the rear wheel gasket (1001).
Remove the caliper as described in Section 06-04.
| Item | Part Number | Description |
|---|---|---|
| 1 | 1012 | Lug Nut |
| 2 | 1007 | Wheel |
| 3 | 1109 | Rear Hub and Rotor Assembly |
| 4 | 2B120 | Disc Brake Caliper |
| 5 | 4001 | Dana Full-Floating Axle, Model 80 |
| 6 | 4A140 | Axle Shaft-to-Rear Hub Bolt |
| 7 | 1001 | Rear Wheel Gasket |
| 8 | 1239 | Outer Bearing Cup |
| 9 | 1243 | Inner Bearing Cup |
| 10 | 1175 | Inner Hub Seal |
| 11 | 1244 | Rear Wheel Bearing Inner Cone and Roller |
| 12 | 1240 | Rear Wheel Bearing Outer Cone and Roller |
| 13 | 1A124 | Hub Nut |
| 14 | 4234 | Axle Shaft |
| A | — | Tighten to 190 Nm (140 Lb-Ft) |
| B | — | Tighten to 113-153 Nm (83-113 Lb-Ft) |
| C | — | Refer to Specifications |
Remove the wheel bearing hub nut using Locknut Wrench T88T-4252-A, so that the drive tangs engage the four slots of the hub nut.
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Valve Stem Alignment Pin (Dual Rear Wheel Only) (Part of 1109) |
| 2 | — | Wheel Pin Locating Hole (Part of 1109) |
| 3 | — | Slot (Part of 1A124) |
| 4 | — | Drive Tang (Part of T88T-4252-A) |
| 5 | T88T-4252-A | Locknut Wrench |
| 6 | 1A124 | Hub Nut |
| A | — | Tighten to 88-102 Nm (65-75 Lb-Ft) while rotating hub. After tightening, ratchet back 90°, then tighten to 20-27 Nm (15-20 Lb-Ft). The maximum torque to rotate the hub is 2-3 Nm (18-27 Lb-In). Wheel end play is 0.00mm (.000 In.). |
Remove the outer bearing cone and pull the rear hub and rotor assembly straight out and away from the rear axle.
Thoroughly clean the spindle of the rear axle housing.
Carefully remove the inner seal from the rear hub assembly with a screwdriver, avoiding damage to the bearing or hub bore.
Discard the seal and remove rear wheel bearing inner cone and roller (1244).
Clean all old grease and axle lubricant out of the rear hub.
Inspect the bearing races and rollers for pitting, galling or erratic wear patterns. Inspect the rollers for end wear. Replace as necessary.
NOTE: To remove hub from rotor, refer to Section 06-04.
Replace the rear hub if any of the following conditions exist:
Remove the inner bearing cup with Inner Bearing Cup Remover T88T-1175-B and Driver Handle T80T-4000-W.
Remove the outer bearing cup with Outer Bearing Cup Remover T88T-1175-A and Driver Handle T80T-4000-W.
Inspect the bearing cups. Replace as necessary.
| Item | Part Number | Description |
|---|---|---|
| 1 | 1175 | Inner Hub Seal |
| 2 | 1244 | Rear Wheel Bearing Inner Cone and Roller |
| 3 | 1240 | Rear Wheel Bearing Outer Cone and Roller |
| 4 | 4234 | Axle Shaft |
| 5 | T88T-1175-C | Bearing Cup Replacer |
| 6 | T75T-1176-A | Threaded Drawbar |
| 7 | — | Forcing Nut (Part of T75T-1176-A) |
Assembly
NOTE: Check for proper seating of the new bearing cups by trying to insert a 0.038mm (0.0015-inch) feeler gauge between the cups and the rear hub. The gauge should not enter beneath the cup. Check in several places to be sure the cups are squarely seated.
Install cups with Bearing Cup Replacer T88T-1175-C and Threaded Drawbar T75T-1176-A.
Attach hub to rotor. Refer to Section 06-04.
Pack each bearing cone and roller assembly with Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. Use a bearing packing tool such as Rotunda Bearing Packer 160-00045 or equivalent.
Place the rear wheel bearing inner cone and roller in the hub.
Install a new inner hub seal with suitable hub seal replacer.
Wrap the threads of the spindle with electrician's tape to prevent damage while installing rear hub.
Position the rear hub at the rear axle housing.
Carefully slide the rear hub over the axle housing spindle. Remove the electrician's tape.
Install the outer wheel bearing cone and roller and start the bearing hub nut making sure the hub tab is properly located in the keyway prior to thread engagement.
NOTE: This procedure is intended to prevent side-to-side end play of the hub and rotor assembly. To verify that there is no side-to-side end play, use a dial indicator magnetically mounted to the spindle end with the indicator on the outboard surface of the hub.
Install the Hub Locknut Wrench T88T-4252-A so that the drive tangs of the tool engage the four slots of the nut. Apply inward pressure to the socket to separate the ratcheting components of the nut, tighten to 88-102 Nm (65-75 lb-ft). Back off 90 degrees, then retighten to 20-27 Nm (15-20 lb-ft). Rotate hub occasionally while tightening to set the bearings.
Prior to installation of the axle shaft, clean and remove any debris in the hub bolt holes.
Inspect axle shaft for:
Replace axle shaft if any of these conditions exist.
Install the caliper. Refer to Section 06-04.
Install the axle shaft and rear wheel gasket.
Using new axle shaft attaching bolts, coat the bolt threads with a suitable thread adhesive and install the bolts until they seat.
Install the wheels.
Remove safety stands and lower the vehicle to the floor.
Tighten the lug nuts to specifications.
Tighten the axle shaft rear hub attaching bolts to 113-153 Nm (83-113 lb-ft).