Dana 4-Wheel Drive Front Axle, F-150 4x4 and Bronco with Coil Springs

Removal

1. Raise the vehicle on a hoist or jack and install safety stands under the radius arm brackets.

2. Remove the wheel and tire assembly and brake caliper. Refer to Section 04-04.

3. On vehicles equipped with four-wheel anti-lock brakes, remove the front brake anti-lock sensor (2C204) from the knuckle. Refer to Section 06-09B.

4. Disconnect the steering linkage from the steering knuckles. Refer to Section 11-03.

5. Remove front driveshaft (4602). Refer to Section 05-01.

6. Remove front stabilizer bar (5482). Refer to Section 04-01B.

7. Position jack under axle arm assembly and remove the upper coil spring retainers. Remove spring lower retainer bolt. Lower the jack and remove the front coil spring (5310), spring cushion and lower spring seat.

8. Disconnect the front shock absorber (18124) at the radius arm and upper mounting bracket.

9. Remove the stud and spring seat at radius arm and axle arm. Remove bolt securing upper attachment to axle arm radius arm to lower attachment axle arm.

10. Disconnect the vent tube at the differential housing and discard the hose clamps. Remove the vent fitting and install a 3mm (1/8-inch) pipe plug.

11. Remove the pivot bolt securing the right axle arm assembly to front crossmember (5019).

    
    
    Front Suspension, F-150 and Bronco 4x4
    
    
    
    
    
    

    Item	Part Number	Description
    1	N806246-S56	Nut and Washer
    2	18198	Shock Absorber Bushing Repair Kit
    3	5B315	Front Spring Seat Upper (LH)
    4	N802210-S	Bolt
    5	N647096-S	Rivet
    6	3B183	Radius Arm Bracket (LH)
    7	N800937-S2	Nut
    8	379572-S2	Washer
    9	34992-S2	Nut
    10	3B463	Radius Arm Heat Shield
    11	3A184	Outer Radius Arm
    12	3B244	Spacer
    13	3B203	Front Radius Arm Insulator
    14	3B186	Front Radius Arm Return
    15	3405	Radius Arm
    16	N605920-S2	Bolt
    17	58740-S100	Screw
    18	3002	Front Axle
    19	18A151	Shock Absorber Lower Bracket (RH)
    20	40954-S100	Screw
    21	3B446	Axle Radius Arm Bracket
    22	390678-S100	Bolt
    23	5A307	Lower Spring Seat with Stabilizer Bar (RH)
    24	5A307	Lower Spring Seat Without Stabilizer Bar (RH)
    25	5A349	Lower Spring Return
    26	388833-S2	Nut
    27	5A333	Upper Spring Return
    28	40949-S2	Screw
    29	5414	Front Spring Insulator
    30	N806496-S100	Nut and Washer
    31	N620482-S36	Nut
    32	18126	Front Shock Absorber Lower Bracket
    33	N805033-S2	Bolt
    34	18045	Front Shock Absorber
    35	N806085-S8	Nut and Washer
    36	380288-S2	Screw and Washer Assembly
    37	N647096-S	Rivet
    38	N803500-S2	Screw
    39	58654-S2	Bolt
    40	34988-S2	Nut
    41	3020	Front Suspension Bumper
    42	65095-S	Rivet
    43	N801079-S2	Bolt
    44	N620604-S100	Nut
    45	N806727-S2	Plate
    46	N801670-S36	Nut
    A	—	Tighten to 34-46 Nm (25-34 Lb-Ft)
    B	—	Tighten to 113-153 Nm (83-113 Lb-Ft)
    C	—	Tighten to 434-461 Nm (320-340 Lb-Ft)
    D	—	Tighten to 26-34 Nm (19-25 Lb-Ft)
    E	—	Tighten to 325-351 Nm (240-259 Lb-Ft)
    F	—	Tighten to 95-135 Nm (70-100 Lb-Ft)
    G	—	Tighten to 35-45 Nm (26-33 Lb-Ft)
    H	—	Tighten to 60-80 Nm (44-59 Lb-Ft)
    J	—	Tighten to 53-72 Nm (39-53 Lb-Ft)
    K	—	Tighten to 212-288 Nm (156-212 Lb-Ft)
    L	—	Tighten to 76-104 Nm (56-77 Lb-Ft)

12. Remove and discard the keystone clamps and remove the boot from the shaft (right side).

13. Remove the right drive axle assembly and pull the axle shaft from the slip-shaft.

14. Position a jack under the differential housing. Remove the bolt securing the left axle assembly to the front crossmember.

15. Remove the left-hand drive axle.

Installation

1. Raise the vehicle on a hoist or a jack. Position the left drive axle assembly on a jack and position to the radius arm. Secure the left drive axle to front crossmember with the pivot bolt. Tighten bolt to 212-288 Nm (156-212 lb-ft).

2. Using a jack, position the right axle assembly at the front crossmember and radius arm. Install the boot on the shaft so the boot seats in the grooves.

3. Position new keystone clamps over the grooves on the boot and crimp the clamp with Keystone Clamp Pliers T63P-9171-A.

4. Align the axle shaft and install in slip-shaft. Secure right axle assembly to front crossmember with pivot bolt. Tighten to 212-288 Nm (156-212 lb-ft).

5. NOTE: Make sure shipping plug has been removed from vent tube. A plugged vent tube can cause leakage past seals or sealant materials.

   Install vent fitting in differential housing. Connect vent tube to vent fitting using new hose clamps. Route vent hose through hole in crossmember and clip to the frame side rail.

6. Position spring seat and install a new upper stud at axle arm and radius arm. Tighten to 325-351 Nm (240-259 lb-ft).

7. Install new bolts (lower) at axle assembly and radius arm. Tighten bolts to 434-461 Nm (320-340 lb-ft).

8. Position front spring insulator (5414) and front coil spring on lower spring seat. Install nuts and tighten to 95-135 Nm (70-100 lb-ft).

9. Position jack under axle assembly and raise front coil spring into position. Install upper spring retainer and screw. Tighten to 35-45 Nm (26-33 lb-ft).

10. Lower the jack.

11. Connect front shock absorbers to upper and lower frame brackets.

12. On vehicles equipped with four-wheel anti-lock brakes, install the front brake anti-lock sensor on the knuckle. Refer to Section 06-09B.

13. Install disc brake caliper (2B120), wheel and tire.

14. Connect the steering linkage. Refer to Section 11-03.

15. Install the front stabilizer bar. Refer to Section 04-01B.

16. Install the front driveshaft. Refer to Section 05-01.

17. Lower the vehicle. Check and adjust camber and toe. Refer to Section 04-00.