Removal & Installation: Spindle: Installation

Ensure kingpin bore is free of nicks, burrs and corrosion. Lightly coat the bore surface with a lithium-based grease. Install kingpin seal with the metal backing facing up toward the bushing.
Gently press seal into position being careful not to distort the casing. Install a new thrust bearing with the lip flange facing down toward the lower bushing. Press until the bearing is firmly seated against the surface of the spindle.
Lightly coat the bushing surface with grease and place spindle in position on the axle. Install the kingpin with the "T" stamped on one end toward the top, and the notch in the pin aligned with the lock pin hole in the axle.
Drive the pin through the bushings and axle from the top until the kingpin notch and axle lock pin hole are aligned. Install the lock pin with the threads pointing forward and the wedge groove facing the kingpin notch.
Firmly drive the lock pin into position and mount the lock washer and nut. Tighten the nut to 38-62 ft. lbs. (52-84 N.m). Install the king pin plugs into the threads at the top and bottom of the spindle. Tighten the plugs to 35-50 ft. lbs. (48-67 N.m).
Lubricate the kingpin and bushings through both fittings until grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the bottom. If grease does not appear, recheck installation procedure.
To complete installation, reverse the remaining removal procedure. Tighten tie rod castellated nut to 70-100 ft. lbs. (94-135 N.m). Check, and if necessary, adjust the toe setting.

Fig 1: F250/350 (2WD) Twin "I" Beam Suspension Van models are similar.

Before assembly, make sure the upper and lower ball joint seals are in place. Place the knuckle over the ball joints. Install the nut on the lower ball joint stud and partially tighten to 35 ft. lbs. (47 N.m).
Install the camber adapter in the upper spindle over the ball joint stud. Ensure adapter is properly aligned. Install nut on upper ball joint stud. Hold the camber adapter with a wrench to keep the ball stud from turning.
Tighten the nut to 85-110 ft. lbs. (116-149 N.m) and insert a new cotter pin. Tighten lower ball joint nut to 140-180 ft. lbs. (190-244 N.m) and insert cotter pin. To complete installation, reverse removal procedure.