Question 1

How to remove and install the front axle on a 4WD Ford Expedition equipped with air suspension?

Accepted Answer

If the vehicle is equipped with air suspension, turn off the air suspension system. The switch is located in the area of the right kick panel. Loosen the wheel lug nuts, raise the front of the vehicle and support it securely on jackstands placed under the frame. Block the rear wheels to keep the vehicle from rolling off the stands. Remove the front wheels. Remove the front driveshaft. Disconnect the front driveaxles from the axleshaft flanges. Disconnect the vacuum lines from the vacuum shift motor. Disconnect the vent hose from the front axle tube. On 2005 and later Expedition/Navigator models, remove the four bolts and remove the front crossmember. Position a jack under the front axle differential case. Remove the front carrier bushing bolts. Remove the four front differential support bolts. Remove the front differential support. Remove the right axle tube bushing bolt. Remove the differential cover bushing bolt. Installation is the reverse of removal. Be sure to tighten all fasteners securely.

Question 2

What are the features and considerations when diagnosing and replacing axles in Ford Expedition?

Accepted Answer

A differential system causes the rear axle assembly to have different wheel speeds while cornering. There are splines on the shafts of the axle, which fit into the differential side gears. For example, drive axles in 4WD models have outer Constant Velocity (CV) joints and inner ones on both sides. An optional locking limited-slip rear axle is available for enhanced traction. When you think about axles as potential sources of noise, don't overlook others like road or tire sounds. This means that engine and transmission noises can also affect diagnosis of any axle issues.

Question 3

How to remove and install the rear axle shaft on a Ford Expedition equipped with air suspension?

Accepted Answer

If the vehicle is equipped with air suspension, turn off the air suspension system. The switch is located behind the right kick panel. Raise the rear of the vehicle, support it securely on jackstands and block the front wheels. Remove the wheel and brake drum or disc. Remove the cover from the differential carrier and allow the lubricant to drain into a container. Remove the lock bolt from the differential pinion shaft. Slide the notched end of the pinion shaft out of the differential case as far as it will go. Position a large screwdriver between the rear axle case and a ring gear bolt to keep the differential case from turning when removing the pinion shaft lock bolt. Rotate the differential case 180-degrees and slide the pinion shaft out of the case until the stepped part of the shaft contacts the ring gear. Push the outer (flanged) end of the axleshaft in and remove the C-lock from the inner end of the shaft. Withdraw the axleshaft, taking care not to damage the oil seal in the end of the axle housing as the splined end of the axleshaft passes through it. Installation is the reverse of removal. The manufacturer recommends that a new pinion shaft lock bolt be used, but if one is not available, coat the threads with a non-hardening thread locking compound. Install the pinion shaft lock bolt and tighten it. Install the differential cover. Install the brake drum or disc/caliper. Refill the axle with the correct quantity and grade of lubricant. Tighten the wheel lug nuts.

Question 4

How to remove and install front driveaxles on Ford Expedition?

Accepted Answer

To remove and install front driveaxles on 2004 and earlier models, turn off air suspension (if equipped), loosen lug nuts, raise vehicle, remove wheel, cotter pin, nut lock, and hub nut. Remove driveaxle flange bolts, steering knuckle, and driveaxle assembly. For installation, follow reverse order, tighten hub nut and CV joint flange bolts, and use new cotter pin. Reactivate air suspension if applicable. On 2005 and later models, remove hub dust cap and driveaxle nut. Loosen lug nuts, raise front of vehicle, support with jackstands, disconnect vacuum tube(s), remove IWE retainer bolts, and disconnect tie-rod end and upper ball joint. Pull steering knuckle outward while pushing inward on driveaxle, use special tool to pull inner driveaxle CV joint away from differential. For rear driveaxles on 2003 and later Expedition/Navigator models, block front wheels, loosen lug nuts, raise rear of vehicle, remove wheel. Depress brake pedal, unscrew driveaxle/hub nut, remove brake disc, suspend brake caliper, remove parking brake cable bolt, cover stabilizer bar link stud threads, detach lower control arm and toe link from rear knuckle. Use puller tool to push driveaxle out of hub, raise lower end of knuckle outward, drive inner end of driveaxle out of differential. For installation, pry off old spring clip, replace it, apply grease, insert splined end of inner CV joint into differential, ensure spring clip locks in place. Apply grease to outer CV joint splines, insert outer end of driveaxle into hub, connect lower control arm and toe link to knuckle, tighten fasteners. Install new driveaxle/hub nut, tighten securely, install parking brake cable, brake disc, and caliper. Have assistant push brake pedal, tighten driveaxle/hub nut, reinstall wheel and lug nuts, lower vehicle, tighten lug nuts.

Question 5

How to remove the Differential and rear axle assembly on Ford Expedition?

Accepted Answer

First of all, to remove the rear axle assembly, turn off the air suspension system if equipped. Loosen the rear wheel lug nuts, lift the rear of the vehicle securely with jack stands, and block the front wheels. Disconnect the rear axle brake lines, vent tube, and brake hose. For truck models, position a floor jack under the differential case, disconnect the shock absorbers, and remove the spring U-bolt nuts, U-bolts, and spring plate. On 4WD models, remove the rear spring spacers while lowering the axle. For Expedition and Navigator models, remove the stabilizer bar brackets, lower the stabilizer bar, disconnect the air suspension system height sensor, and support the rear axle differential case with a floor jack. Disconnect the rear axle track bar, remove the rubber jounce bumper, and disconnect suspension arms and shock absorbers. Lower the axle assembly to the floor.

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