Removal & Installation

WARNING: This page is about a different car, the 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, 2002 Ford Excursion, and 2002 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Raise and support the vehicle. Index mark the front drive shaft to the front differential flange. See Fig 1. Index mark the front drive shaft to the transfer case pinion flange. See Fig 2. Remove and discard the "U" joint retainers and bolts.

NOTE: Wrap electrical tape around the "U" joints to prevent the "U" joint bearing cups from falling off the "U" joint.

Remove and discard the 4 drive shaft-to-transfer case pinion flange bolts. Remove the front drive shaft by compressing and separating the front drive shaft from the front axle pinion flange, then separate the front drive shaft from the transfer case pinion flange. See Fig 3.
To install, reverse the removal procedure. Install the front drive shaft with the index marks aligned. See Fig 1 and Fig 2 . An extension must be used to tighten the front drive shaft-to-transfer case pinion flange bolts. Extensions change the calibration of the torque wrench. See Fig 4. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Use the torque wrench manual to calculate the correct settings. Install NEW "U" joint bolts and retainers.

Fig 1: Identifying "U" Joint Retainers

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Drive Shaft-To-Transfer Case Pinion Flange

Courtesy of FORD MOTOR CO.

Fig 3: Removing & Installing Front Drive Shaft

Courtesy of FORD MOTOR CO.

Fig 4: Identifying Torque Wrench Extension

Courtesy of FORD MOTOR CO.