I tried to remove one of the front wheels from my van and can't get the wheel off the hub after taking the lug bolts off. It looks like there is very tight fit on the raised area on the hub and the inside wheel hole. I think I can use a piece of wood and a sledge hammer to get it off but that can't be a normal thing to have to do to change a tire. The real wheels seem to go on fine since there is no raised area for the inside hole to bind to. WOuld it be wise to grind out a little of the inside hole on the front 2 wheels and the spare?
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Re: 1989 E-250 Front Wheel Problem
Spray some penatrating oil around the center of the wheel, and let it sit for a few min.With the tire off the ground, rap on the back side of the tire, on the edge of the rim, but be careful not to rap it to hard, as you might dent the rim.It won't hurt to grind a little bit, just enough to remove the rust. I do it all the time.Hope I could help out.
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Hub and BearingRemoval & InstallationNOTE: The removal and installation of the wheel bearing and hub from the steering knuckle is only to be done with the steering knuckle removed from the vehicle To Remove:
Remove the steering knuckle and hub and bearing assembly.
Remove a wheel lug stud from the hub flange using a C-clamp and Adapter Tool 4150A or equivalent.
Rotate the hub to align the removed lug stud with the notch in the bearing retainer plate.
Use a proper C-clamp and adapter tool to press out one of the lug studs
Rotate the hub in order to remove the lug stud
Rotate the hub so the stud hole is facing away from the brake caliper's lower rail on the steering knuckle.
Install ½ of a Bearing Splitter Tool 1130 or equivalent between the hub and the bearing retainer plate. The threaded hole in this ½ is to be aligned with the caliper rail on the steering knuckle.
Install the remaining pieces of the bearing splitter on the steering knuckle. Hand-tighten the nuts to hold the splitter in place on the knuckle.
Proper installation of the bearing splitter
When the bearing splitter is installed, be sure the 3 bolts attaching the bearing retainer plate to the knuckle are contacting the bearing splitter. The bearing retainer plate should not support the knuckle or contact the splitter.
Place the steering knuckle in a hydraulic press, supported by the bearing splitter.
Properly support the steering knuckle for hub and bearing removal
Position a driver on the small end of the hub. Using the press, remove the hub from the wheel bearing. The outer bearing race will come out of the wheel bearing when the hub is pressed out of the bearing.
Remove the bearing splitter tool from the knuckle.
Place the knuckle in a press supported by the press block. The blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the knuckle. Place a driver on the outer race of the wheel bearing, and then press the bearing out of the knuckle.
Install the bearing splitter on the hub. The splitter is to be installed on the hub so it is between the flange of the hub and the bearing race on the hub. Place the hub, bearing race and splitter in a press. Use a driver to press the hub out of the bearing race.
Use clean, dry cloth to wipe and grease or dirt from the bore of the steering knuckle.
Clean the rust preventative from the replacement wheel bearing using a clean, dry towel.
Place the new wheel bearing into the bore of the steering knuckle. Be sure the bearing is placed squarely into the bore. Place the knuckle in a press with a receiver tool, C-4698-2 or equivalent supporting the steering knuckle. Place a driver tool on the outer race of the wheel bearing. Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle.
NOTE: Only the original or original equipment replacement bolts should be used to mounting the bearing retainer to the knuckle. If a bolt requires replacement when installing the bearing retainer plate, be sure to get the proper type of replacement.
Install the bearing retainer plate on the steering knuckle. Install the 3 bearing retainer mounting bolts. Torque the bolts to 21 ft-lbs (28 Nm).
Install the removed wheel lug stud into the hub flange.
Place the hub with the lug stud installed, in a press supported by Adapter Tool C-4698-1 or equivalent. Press the wheel lug stud into the hub flange until it is fully seated against the back side on the hub flange.
Place the steering knuckle with the wheel bearing installed, in a press with special Receiver Tool MB-990799 or equivalent supporting the inner race of the wheel bearing. Place the hub in the wheel bearing, making sure it is square with the bearing. Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing.
About an hour a side...This is the whole job and pictures....
The hub and wheel bearing unit is serviced as a complete assembly. Replacement of the front drive hub and bearing assembly can be done without having to remove the steering knuckle from the vehicle. However, if the hub/bearing assembly is frozen to the steering knuckle, removal of the steering knuckle is required.
Disconnect the negative battery cable.
Remove the cotter pin from the end of the stub axle. Remove the nut lock and spring washer. With the brakes applied, loosen, but do NOT remove the axle nut and washer with the vehicle still on the ground or damage to the wheel bearing will result.
Raise and safely support the vehicle. Remove the wheel.
Remove the front brake caliper assembly from the steering knuckle assembly and support from the strut assembly using a strong piece of wire.
Remove the front brake rotor from the hub/bearing assembly.
Remove the retaining nut and washer from the halfshaft stub axle.
Remove the ABS wheel speed sensor from the steering knuckle.
Remove the 4 hub and bearing assembly mounting bolts from behind the steering knuckle.
Remove the hub and bearing assembly from the steering knuckle.
Thoroughly clean the mating surfaces of the steering knuckle and the hub and bearing assembly of any foreign material or nicks so the surfaces are clean and smooth.
Install the new hub and bearing assembly and tighten the mounting bolts in a crisscross pattern to 45 ft. lbs. (65 Nm). Be sure the hub and bearing assembly is seated squarely against the front steering knuckle.
Install the disc brake rotor.
Install the brake caliper assembly onto the steering knuckle.
Install the axle washer and nut. Tighten but do not torque.
Install the ABS wheel speed sensor.
Install the wheel and lug nuts. Torque the lug nuts, in sequence, to 95 ft. lbs. (129 Nm).
Lower the vehicle. Do NOT roll the vehicle until the axle nut has been properly torqued or damage to the front wheel bearings will result.
With the vehicle's brakes applied, torque the axle nut to 180 ft. lbs. (244 Nm). Install the spring washer, nut lock and a new cotter pin. Wrap the cotter pin prongs tightly around the axle nut lock.
Reconnect the negative battery cable. Check the wheel alignment.
The hub/bearing assembly is attached to the steering knuckle with four bolts
Removing a hub/bearing assembly
If the hub/bearing is "frozen" to the steering knuckle, separate the ball joint and lightly tap on the hub/bearing from behind
The hub/bearing assembly should free itself from the steering knuckle
I'll try to help you. If you are having trouble with 3 out of 5 studs on one wheel you may want to go to an autoparts store or Salvage yard to look at the whole hub. Usually a press is used to remove the bolts so you would be taking off the hub anyway. When you pay for 3 bolts and labor you may be better off in a Salvage yard or parts place for a different hub. The rear hub on front wheel drive cars is like a trailer axle. Much simpler to remove mounting bolts and press in new bolt. But if rear has differential(rear wheel drive) it has an axle shaft. Would be easier to grind and drill out broken stud on car. You can draw new bolt into place by placing bolt through a socket and use the wheel nut to draw the bolt into the hub.
Hub and Bearing Assembly
CAUTION: Do not begin this removal procedure unless the following parts are available:
A new front axle wheel hub retainer (3B477) (Step 1).
A new inboard halfshaft joint stub shaft circlip.
Once removed, these parts must not be reused during assembly. Their torque holding ability or retention capability is diminished during removal. Removal
Turn ignition switch to the OFF position and place the steering column in the unlock position.
CAUTION: Discard the front axle wheel hub retainer. It is a torque prevailing design and cannot be reused. If loosened, the retainer must be removed and a new one installed.
Remove and discard front axle wheel hub retainer (3B477).
Raise vehicle on hoist.
NOTE: Make sure steering column is in the unlocked position, and do not use a hammer to separate tie rod end (3A130) from the front wheel knuckle (3K185) . Use extreme care not to damage boot seal.
Remove cotter pin from tie rod end stud and remove slotted nut. Discard cotter pin and nut.
Using Tie Rod End Remover 211-001 (TOOL-3290-D) or equivalent and Tie Rod End Remover Adapter 211-087 (T81P-3504-W), remove tie rod end from front wheel knuckle.
CAUTION: Use extreme care not to damage boot seal. Do not use power tools to remove the nut, or bearing and seal damage will result. Loosen the nut first, then remove nut from stud using the hex hold feature.
For SHO vehicles, remove vinyl cover from upper link stud.
Remove stabilizer bar link (5K484) from front shock absorber (18124) .
Remove disc brake caliper (2B120) and support with wire to obtain working space. Do not allow disc brake caliper to separate from the front disc brake caliper anchor plate (2B292) to prevent contamination of the disc brake guide pin journals. Do not allow disc brake caliper to hang from front brake hose (2078) . Remove front disc brake rotor (1125) . Remove front disc brake rotor from wheel hub (1104) by pulling it off the lug bolt (1107). If front disc brake rotor is difficult to remove from front wheel knuckle , strike front disc brake rotor sharply between lug bolt with a rubber or plastic hammer.
If front disc brake rotor will not pull off, apply Rust Penetrant and Inhibitor D7AZ-19A501-AA or equivalent meeting Ford specification ESR-M99C56-A to inboard and outboard rotor/hub mating surfaces. Install 3-Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove front disc brake rotor by pulling on front disc brake rotor outside diameter and pushing on hub center. If excessive force is required for removal, check front disc brake rotor for lateral runout prior to installation. Refer to Section 06-00.
Remove anti-lock brake sensor mounting bolt and front brake anti-lock sensor (2C204) .
Remove and discard lower ball joint nut. Using Remover Adapter 211-211 (T96P-3010-A1), separate lower ball joint from front suspension lower arm (3078) .
Using Rotunda Spring Compressor 014-00781 or equivalent, compress front coil spring (5310) until lower ball joint clears front suspension lower arm .
Using Front Hub Remover/Replacer 204-069 (T81P-1104-C), Two Stud Adapter 205-237 (T86P-1104-A1), Metric Hub Remover Adapter 204-085 (T83P-1104-BH) and Front Hub Installer 204-067 (T81P-1104-A), press front wheel driveshaft joint (3B414) from wheel hub . Wire front wheel driveshaft joint to body to maintain a level position.
Metric Hub Remover Adapter
Front Hub Replacer
Turn Wrench Counterclockwise
Hold Wrench Stationary While Turning Other Wrench
Front Hub Remover/Replacer
Two Stud Adapter
Make Sure Metric Hub Remover Adapter 204-085 (T83P-1104-BH) is Fully Threaded onto 1107 and is Positioned Opposite the Two Stud Adapter 205-237 (T86P-1104-A1)
Remove and discard three hub and bearing retainer bolts from front wheel knuckle .
NOTE: Wheel hub is not pressed into front wheel knuckle . Do not use slide hammer to remove a stuck wheel hub . Do not strike back of inner bearing race. Use of these methods will damage bearing internal parts.
NOTE: If bearing carrier is corroded to front wheel knuckle , apply Rust Penetrant and Inhibitor D7AZ-19A501-AA or equivalent meeting Ford specification ESR-M99C56-A to the inboard and outboard wheel hub/knuckle mating surface and allow to soak.
Remove wheel hub from front wheel knuckle .
NOTE: If wheel hub is damaged or if any end play is detectable, replace wheel hub . End play is not adjustable. If wheel hub is disassembled, the assembly must be replaced.
Remove all foreign material from knuckle bearing bore for correct seating of new wheel hub.
Lightly lubricate mating surfaces of bearing corner and front wheel knuckle.
CAUTION: Knuckle bore must be clean enough to allow wheel hub to be completely seated by hand. Do not press or draw wheel hub into place.
Position wheel hub in front wheel knuckle . Install three new hub and bearing retaining bolts. Tighten to 83-107 Nm (61-78 lb-ft).
Push front wheel driveshaft joint into wheel hub . Hand start front wheel hub retainer.
Slowly release Rotunda Spring Compressor 014-00781 or equivalent while guiding lower ball joint into front suspension lower arm .
Install new lower ball joint nut. Tighten to 68-92 Nm (50-67 lb-ft).
Install tie rod end into front wheel knuckle . Install new slotted nut and tighten to 47-63 Nm (35-46 lb-ft). If necessary advance nut to install a new cotter pin.
CAUTION: Use extreme care not to damage boot seal. Do not use power tools to tighten nut or bearing and seal damage will result. Install nut using hex hold feature to prevent the stud from rotating.
Install stabilizer bar link to front shock absorber . Install stabilizer bar link nut. Tighten to 77-103 Nm (57-75 lb-ft). For SHO vehicles, install stud cover.
NOTE: Remove rust from the rotor and hub mating surfaces with a medium abrasive pad.
Install front disc brake rotor and disc brake caliper . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
CAUTION: The front axle wheel hub retainer must be tightened to specification immediately during installation. If the retainer is not tightened immediately, the nylon lock will set incorrectly, leading to incorrect torque readings and bearing failure. Any front wheel hub retainer that is not immediately tightened to specification or is loosened must be removed and a new retainer installed.
Install front axle wheel hub retainer . Tighten to 230-275 Nm (170-203 lb-ft).
Install wheel and tire. Tighten lug nuts (1012) to 115-142 Nm (85-104 lb-ft).
Pump brake pedal prior to moving vehicle to position brake linings.
Section 04-01: Suspension and Wheel Hubs, Front
1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Wheel Hub Bolt
Raise vehicle on hoist.
Remove wheel and tire assembly. Refer to Section 04-04 .
Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
Brake Shoe and Lining
Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
Raise vehicle on hoist. Refer to Section 00-02 .
Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
NOTE: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
Remove inner brake shoe and lining assembly.
Position lug bolt (1107) to clear front wheel knuckle (3K185).
Remove lug bolt from wheel hub (1104).
Install lug bolt into wheel hub.
Using a lug nut (1012), seat wheel hub bolt into wheel hub.
Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).