Dana 4-Wheel Drive Front Axle, F-250 4x4 with Leaf Spring Front Suspension

Removal

1. NOTE: When raising the vehicle on a hoist, make sure that the hoist lift points do not rest on the caliper pins.

   Raise vehicle on a hoist or jack and install safety stands.

2.  CAUTION: Do not let the disc brake caliper (2B120) hang with its weight on the brake hose or the hose may become stretched or twisted.

   Remove the wheels (1007) and tires, and disc brake calipers. Refer to Section 06-03.

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

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

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

6. Position jack under right-hand axle assembly. Remove the two U-bolts securing the shock absorber mounting plate and front spring to axle arm.

7. Disconnect the vent tube at the differential housing. Remove the vent fitting and install a 3mm (1/8-inch) pipe plug or a vacuum fitting cap.

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

9. Remove the pivot bolt that secures the right-hand axle assembly to front crossmember (5019).

10. Remove the right axle assembly. Pull the axle shaft out of the slip-shaft.

11. Position the jack under the left-hand axle assembly. Remove the two U-bolts securing the shock absorber mounting plate and front spring to tube and yoke assembly.

12. Position a jack under the differential housing.

13. Remove the pivot bolt securing the left-hand axle assembly to front crossmember. Remove the left axle assembly.

    
    
    F-250 4x4, Leaf Spring Front Suspension
    
    
    
    
    
    

    Item	Part Number	Description
    1	3590	Steering Gear Sector Shaft Arm
    2	800895-S56	Nut
    3	N620483-S2	Cotter Pin
    4	5310	Front Leaf Spring
    5	N800021-S2	Bolt
    6	N806496-S301	Nut
    7	18183	Front Shock Absorber Mounting Bracket
    8	N802114-S2	Bolt
    9	18124	Front Shock Absorber
    10	5458	Front Spring Plate Spacer
    11	5A500	U-Bolt Spacer
    12	801342-S2	Nut
    13	N805073-S56	U-Bolt
    14	3020	Front Suspension Bumper
    15	N620483-S2	Nut
    16	3B251	Front Axle Bumper Bracket
    17	N620482-S2	Nut
    18	N605933-S2	Bolt
    19	N802114-S2	Bolt
    20	N802073-S2	Nut
    21	3B176	Front Axle Pivot Bracket (RH)
    22	N801079-S2	Bolt
    23	N808528-S100	Bolt and Retainer
    24	N620604-S100	Nut
    25	3K090	Front Axle Bearing Bracket (LH)
    26	N802073-S2	Nut
    27	N601522-S2	Bolt
    28	N620485-S56	Nut
    29	N620484-S56	Nut
    30	5L302	Spring Insulator Sleeve
    31	5K316	Front Spring Front Shackle
    32	N800991-S2	Bolt
    33	58634-S2	Bolt
    34	44877-S2	Washer
    35	5340	Front Spring Mounting Bracket
    36	N647097-S	Rivet
    37	34987-S2	Nut
    A	—	Tighten to 77-103 Nm (57-80 Lb-Ft)
    B	—	Tighten to 60-80 Nm (44-59 Lb-Ft)
    C	—	Tighten to 113-153 Nm (83-113 Lb-Ft)
    D	—	Tighten to 88-118 Nm (65-87 Lb-Ft)
    E	—	Tighten to 149-201 Nm (110-148 Lb-Ft)
    F	—	Tighten to 170-230 Nm (125-170 Lb-Ft)
    G	—	Tighten to 47-78 Nm (35-60 Lb-Ft)

Installation

1. Raise vehicle on a hoist or a jack and position left axle assembly at front leaf spring. Install the pivot bolt that secures the axle assembly to the front crossmember.

2. Secure the shock absorber mounting plate to the front leaf spring and axle assembly with the two U-bolts. Tighten bolts to 113-153 Nm (83-113 lb-ft).

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. Position the right-hand axle assembly at front crossmember. Install the boot on the shaft so the boot seats in the grooves. Install the pivot bolt that secures the axle assembly to front crossmember. Tighten bolt to 149-201 Nm (110-148 lb-ft).

5. Install shock absorber mounting plate, front leaf spring and axle assembly using two U-bolts. Tighten bolts to 113-153 Nm (83-113 lb-ft).

6. Install vent fitting to differential housing and connect vent tube to vent using a new hose clamp.

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

8. Install disc brake caliper and wheel and tire. Refer to Section 06-03.

9. Install front driveshaft. Refer to Section 05-01.

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

11. Check and adjust caster, camber and toe.