Section 05-03B: Axle, Front Drive, Dana Model 60 Monobeam
1996 F-350 4x4 Workshop Manual
REMOVAL AND INSTALLATION

Axle Shaft

 
SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Spindle Bearing ReplacerT80T-4000-R
Driver HandleT80T-4000-W
Spindle Seal ReplacerT92T-4000-A
Shaft Seal ReplacerT95T-3132-B
Driver HandleT83T-3132-A1

 

Removal

  1. Raise the front of the vehicle and install safety stands.

  1. Remove the lug nuts (1012) and remove the front wheel (1007) and tire.



    Dana Model 60 Monobeam Front Drive Axle — Typical





    ItemPart NumberDescription
    13220Axle Shaft Assembly
    23C132Axle Shaft Rolling Diaphragm Seal (RDS)
    33299Integral Spacer/Seal
    43123Caged Needle Bearing
    54571Nut
    6—Front Disc Brake Hub
    (Part of 1102)
    71239Outer Bearing Cup
    81240Wheel Bearing — Outer
    91197Outer Lock Nut
    101B198Inner Lock Nut
    111198Lockwasher
    121243Inner Bearing Cup
    131244Wheel Bearing — Inner
    141190Wheel Hub Grease Seal
    153105Front Wheel Spindle

  1.  CAUTION: After removal, the disc brake caliper (2B120) must be wired to the frame or otherwise supported to prevent suspending the disc brake caliper by the flexible hose. If securing the disc brake caliper is not practical, disconnect and plug the hose to the disc brake caliper. Upon installation, bleed the system as described in Section 06-06.

    Remove the disc brake caliper. Refer to Section 06-03 in the Body, Chassis Manual. Securely wire the disc brake caliper to the frame.

  1. Remove wheel hubs, bearings, and lock nuts. Refer to Section 05-03C.

  1. Remove the front disc brake hub and rotor (1102) from the front wheel spindle (3105).

  1. NOTE: Relieve the suction between the axle shaft rolling diaphragm seal (RDS) and the front wheel spindle by gently lifting the seal lip away from the back of the front wheel spindle which will allow the front wheel spindle to slip off the axle shaft.

    Remove the nuts retaining the front wheel spindle to the knuckle. Lightly tap the front wheel spindle with a rawhide hammer to remove from the knuckle.









  1. Remove the front disc brake rotor shield (2K004) from the knuckle.

  1.  CAUTION: Extreme care must be taken when removing or installing axle shafts to avoid damaging axle housing trunion seals.

    Pull the axle shaft assembly out of the steering knuckle.





  1. NOTE: Actuator pin may travel far enough up and contact bridge. If this occurs, remove bridge and use a slide hammer to complete removal.

    If required, remove the caged needle bearing seal, and integral thrust washer from the front wheel spindle. Pull the bearing out of the front wheel spindle using Collet (1-1/2 to 1-3/4 inch) D80L-100-U, Actuator Pin D80L-100-H and Bridge Assembly D80L-100-W or equivalents.






    ItemPart NumberDescription
    1D80L-100-UCollet (1-1/2 to 1-3/4 Inch)
    2D80L-100-WBridge
    3D80L-100-HActuator Pin
    43123Bearing
    53105Front Wheel Spindle
 

Installation

  1. NOTE: Replacement spindle bearings are shipped with a corrosion-preventive gel. This is not a lubricant. Bearing must be cleaned and repacked with the specified grease.

    If removed, pack a new bearing with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.

  1. NOTE: The writing on the bearing must face the inboard side of the front wheel spindle, toward the driving tool.

    Position the bearing in the bore of the front wheel spindle.

  1. Drive the bearing in the front wheel spindle with Spindle Bearing Replacer T80T-4000-R and Driver Handle T80T-4000-W until the tool bottoms out against the front wheel spindle.





  1. Install the thrust washer/seal assembly using Spindle Seal Replacer T92T-4000-A.





  1.  CAUTION: Do not bend the sheet metal portion of the seal.

    Install the rolling diaphragm seal on the axle shaft. Seat the rolling diaphragm seal by lightly tapping on the inner sheet metal lip of the seal with Shaft Seal Replacer T95T-3132-B, Driver Handle T83T-3132-A1, and a hammer to make sure that it is seated squarely.





  1. Lightly coat the lips of the axle shaft rolling diaphragm seal (RDS) and the mating surface of the front wheel spindle with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.





  1. NOTE: Relieve the suction between the axle shaft rolling diaphragm seal (RDS) and the front wheel spindle by gently lifting the seal lip away from the back of the front wheel spindle which will allow the front wheel spindle to slip off the axle shaft.

    Carefully guide the axle shaft through knuckle and into the axle housing. Check that the splines of the axle shaft are engaged in the differential side gear splines.





  1. Install the front disc brake rotor shield on the steering knuckle.

  1. Place front wheel spindle on the steering knuckle. Install nuts and tighten to 68-81 Nm (50-60 lb-ft).





  1. Install the front disc brake hub and rotor on the front wheel spindle, inspecting the wheel bearings and grease seal, and making sure there is adequate lubrication with High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A.

  1. Install bearing, lock nuts, and hub locks. Refer to Section 05-03C.

  1. Install the disc brake caliper. Refer to Section 06-03.

  1. Install the front wheel and tire. Install the lug nuts and tighten to specification. Refer to Section 04-04.