How do I remove the front axle shafts in a 2003 Dodge 2500 4x4?
I'm in th process of replacing the ball joints, the axle shafts need to be removed for this. Something appears to be locking them in. I don't see any snap rings or clips on the shaft ends inside the differential. How do they come out?
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these ball joints require a ball joint press loosen axle nut then remove wheels, front brake caliper and mount. now there are 3 bolts that hold the wheel bearing hub assembly on remove if has ABS then remove wiring harness with hub (you have to hammer free) once off then side axle shaft out hole. remove both nuts that hold ball joints to steering knuckle and differential install press and remove and install then reassemble NOTE rent a ball joint press or buy a cheap one from harbor freight.
The lower control arm is a two-piece welded unit with a riveted ball joint. A conventional rubber bushing is used for the rear lower control arm pivot. The front lower control arm bushing is mounted vertically.
REMOVAL AND INSTALLATION
Some special tools are required to perform this operation including, a front hub spindle removal tool and a suitable ball joint separator tool.
Do not hammer or pry ball joint from knuckle. Failure to use recommended tools may cause damage to the ball joint and seal.
See Figure 1
Fig. Fig. 1: Exploded view of the control arm-to-frame mounting
Raise the vehicle and suitably support by the frame allowing the control arms to hang free.
Remove the wheel and tire assembly.
Remove the steering gear outer tie rod from the steering knuckle.
Remove the stabilizer shaft link from the control arm.
Remove the front drive axle shaft nut and washer.
Use a suitable front hub spindle removal tool to Push the axle splines back out of the front wheel drive shaft bearing.
Remove the drive axle from the transaxle.
Drive axle joint seal protectors should be used anytime service is performed on or near the drive axles. Failure to observe this could result in joint or seal failure.
Place a modified inner drive joint seal protector on the drive axle joints.
If equipped, remove the ABS wheel speed sensor jumper harness.
Remove and discard the cotter pin, then loosen the nut from the ball stud.
Remove the pinch bolt and the control arm mounting bolts, then remove the control arm from the vehicle.
remove the right front wheel. remove the axle nut. remove the ball joint bolt and nut. remove the ball joint from the knuckle. drive the axle out of the hub. remove the 2 carrier bearing nuts. pull the axle out. make sure you torque all bolts and nuts.
Raise the front of the vehicle and install safety stands.
Remove the wheel and tire assembly. Refer to Section 04-04 .
Remove the disc brake caliper (2B120) from the rotor and wire it out of the way. Refer to Section 06-03 .
Remove the dust cap, cotter pin, nut retainer, nut, washer and front wheel bearing (1216).
Remove the rotor from the front wheel spindle (3105).
Front Suspension Upper Ball Joint
Front Suspension Lower Arm Ball Joint
Front Wheel Spindle
Steering Sector Shaft Arm Drag Link
Front Axle Assembly
Tighten to 77-103 Nm (57-75 Lb-Ft)
Tighten to 68-92 Nm (50-67 Lb-Ft)
Tighten to 113-153 Nm (83-112 Lb-Ft)
Tighten to 340-460 Nm (250-339 Lb-Ft)
Remove bearing cone and roller (1201) and wheel hub grease seal (1190). Discard the seal.
Remove front disc brake rotor shield (2K004). Refer to Section 06-03 .
Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with Tie Rod End Remover TOOL-3290-D or equivalent.
Remove the cotter pin and castellated nut from the lower ball joint stud.
Remove the nut from the axle clamp bolt and remove the bolt from the axle.
Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool D81T-3010-B or equivalent to remove adjuster.
CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket.
Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam.
Remove the front wheel spindle and ball joint from the axle.
Ball Joint, F-150, F-250, F-350
SPECIAL SERVICE TOOL(S) REQUIRED
Ball Joint Remover
Remove the front wheel spindle (3105) and ball joint assembly from the axle. Refer to Wheel Spindle, F-150, F-250, F-350 in the Removal and Installation portion of this section.
NOTE: Lower ball joint must be removed first.
Install the front wheel spindle in a vise and remove the snap ring from the lower ball joint.
Remove the lower ball joint from the front wheel spindle using U-Joint Tool T74P-4635-C and Receiver Cup D81T-3010-A5 or equivalent for F-150. Use Ball Joint Remover T94T-3010-AH for F-250 and F-350.
Turn the forcing screw clockwise until the ball joint is removed from the front wheel spindle.
CAUTION: Do not heat the ball joint or the front wheel spindle to aid in removal.
Assemble U-joint tool and cup on the upper ball joint, and turn forcing screw clockwise until ball joint is removed from the front wheel spindle.
CAUTION: Do not heat the ball joint or axle to aid in installation. NOTE: Upper ball joint must be installed into the front wheel spindle first.
NOTE: Individual ball joint tools are included in Ball Joint Adapter Set D81T-3010-A or equivalent.
To install the upper ball joint, assemble C-frame assembly, Ball Joint Receiver Cup D81T-3010-A5 and Installation Cup D81T-3010-A1 and D81T-3010-A3 or equivalents inside cup D81T-3010-A4 or equivalent in position on the front wheel spindle.
Turn forcing screw clockwise until ball joint is seated.
remove passenger side wheel remove center nut on axle shaft i believe a 33 mm remove cotter pin on lower ball joint remove nut on lower ball joint with a ball joint seperating tool(pickle fork) seperate lower ball joint might need to tap axle shaft out of the wheel bearing pull the whole assembly aside where the axle goes into the transmission use a pry bar and pry out on the axle sometimes are stuck in pretty good then reverse the procedure to install be sure to torqe axle nut to specefications
good luck chris
to remove the axles, remove brake caliper and disc, remove hub assembly, the center hub/axle nut and...(there are i think 3-4 bolts on the back side of the spindle to remove the hub), you may have to force the hub off the spindle with a hammer or air hammer... once the hub is out the axle should slide out of the front differential allowing access to the ball joint nuts for removal...
That works fine on a relatively new vehicle but one that has run in salt etc you'll save a lot of time if you remove the steering knuckle completey by separating lower ball joint and outer tie rod end ball joint and bring the whole steering knuckle to a bench to separate the hub/bearing. Soak everything with penetrant, loosen the bolts a few turns and try hitting right on the bolt heads. I also made a very sharp wedge from a chisel and rammed it hard on the other side to seoarate the hub. It will finally come apart then you'll see all the **** that was binding it due to an alumininum knuckle re-acting with a steel hub. Clean the hole and grease everything and fit new bearings