Suspension - Front (4wd Leaf) Ford Cab & Chassis Ranger

DESCRIPTION

The 4WD independent front suspension (IFS) system has a 2-piece drive axle attached to frame with 2 semi-elliptic leaf-type springs. Each spring assembly is clamped to axle arm assembly with 2 "U" bolts. Rear spring eye is attached to hanger bracket and front spring eye is attached to shackle bracket. The 2 direct, double-action hydraulic shock absorbers are attached to each frame bracket at top and to "U" bolt spring spacer plate at bottom. (Scheme 16)

Either manual or automatic hub locks are installed on 4WD vehicles to activate the front drive axle. When actuated, hub lock body assembly locks hub and wheel assembly to front drive axle shaft. When released, axle shaft is disengaged from hub body assembly and hub is allowed to rotate freely on spindle. Two tapered roller bearings are mounted in hub with a hub grease seal installed inboard of inner bearing.

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES

All F-250/350 models use a stamped axle housing, independent front suspension design with adjustable camber angle. On front leaf spring suspensions, caster angles are adjustable by placing shims between the leaf springs and the axle housing arm assembly. Toe-in is checked and set in the conventional manner. See RIDE HEIGHT and WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT section.

WHEEL BEARING ADJUSTMENT

Note. If bearing adjustment does not eliminate looseness or rough and/or noisy operation, remove, clean, inspect and repack hub and bearings with specified grease. If bearing races or roller assemblies are worn or damaged, they must be replaced.

Dana 50 Series Front Drive Axle (With IFS)

1. Raise and support vehicle on safety stands. Hold tire at front and rear, then push tire inward and outward. If any free play is noticed between hub/rotor assembly and spindle, adjust wheel bearings.
2. Remove manual or automatic hub lock assembly and outer lock nut with washer. See REMOVAL & INSTALLATION. Using Front Wheel Bearing Spanner (D78T-1197-A) and a torque wrench, tighten inner adjusting nut to 50 ft. lbs. (68 N.m).
3. Back-off inner adjusting nut, then retighten to 31-39 ft. lbs. (41-54 N.m). While rotating hub, back-off adjusting nut 135° to 150°. Assemble outer lock nut and new lock washer, then tighten nut to 65 ft. lbs. (88 N.m).
4. Bend 1 ear of lock washer over inner nut and the other ear of lock washer over outer nut. Install a dial indicator and check hub end play. Final end play should be .001-.009" (.02-.25 mm).
5. If end play is beyond limits, remove hub and bearing assembly and inspect components for excessive wear or damage. Replace hub and/or bearing assemblies as necessary. Reinstall components and adjust wheel bearings. Install hub lock assembly. Remove safety stands and lower vehicle.

BALL JOINT CHECKING

1. Raise and support vehicle on frame hoist. Hold tire at top and bottom, then shake wheel while watching for movement of disc brake support or spindle assembly.
2. If front spindle assembly is loose and moves more than 1/32" (.79 mm) at upper or lower arms (relative to axle), replace upper and/or lower ball joint as necessary.

Scheme 16

1. Raise and support vehicle. To remove locking hub assembly, first separate locking hub cap assembly from body assembly. Using a Torx-R bit (TX25), detach 5 cap screws from cap assembly, then remove locking hub cap and bearing components. CAUTION: Do not drop ball bearing, race, spring retainer or spring during disassembly.
2. Remove rubber sealing ring. Remove seal bridge retainer (small metal stamping) from spring retainer ring space. Detach lock ring retainer by closing ends with needle-nose pliers while pulling locking hub body assembly from wheel hub. (Scheme 16)
3. If wheel hub and spindle are to be removed, detach "C" washer from stub shaft groove. Remove splined spacer from shaft. Remove wheel bearing lock nuts and lock washer. (Scheme 16) Disassemble, clean and inspect locking hub assembly components. (Scheme 16): Exploded View Of Warner Gear Automatic Locking Hub Assembly
4. Detach snap ring and flat washer from inner end of locking hub assembly. (Scheme 18) Pull hub sleeve and attached parts out of drag sleeve, then cock drag sleeve to unlock tangs of brake band. Remove drag sleeve assembly. (Scheme 18) CAUTION: Do not remove brake band from drag sleeve.
5. Wash drag sleeve/brake band assembly in clean solvent and thoroughly blow dry. Lubricate brake band/drag sleeve assembly with lubricant meeting specification ESL-M1C93A (Darmex Spec. DX-123-LT). Work lubricant over spring and area of drag sleeve under spring.
6. Dip locking hub body assembly (except cap assembly and brake band/drag sleeve assembly) in Dexron II Automatic Transmission Fluid and permit to drip dry for a few minutes before proceeding with assembly.

Inspection

Wash locking hub cap bearing, race and retainer in clean solvent, then inspect for excessive wear or damage. Replace components as needed. Thoroughly blow dry parts with compressed air. Do not spin bearings with air or damage can result. Repack bearing with lithium grease, then properly position bearing assembly in race. (Scheme 17)

Positioning Locking Hub Cap Bearing, Race & Spring Retainer Position inner race into bearing assembly, then install bearing retainer as shown. Scheme 17

Scheme 18

1. To install locking hub components, first assemble 1 of 2 brake band tangs on each side of outer cage (plastic), which is located in window of inner cage (steel). It is necessary to cock these parts to engage tangs in this position as the drag sleeve is positioned against cam follower face. Install washer and snap ring. (Scheme 18) (Scheme 18): Checking Position Of Brake Band & Drag Sleeve Assembly To Locking Hub Body Assembly
2. If removed, install wheel bearing inner adjusting nut and lock washer. Tighten outer lock nut to 150 ft. lbs. (203 N.m). Install splined spacer and "C" washer onto axle shaft. NOTE: Remove excess grease from hub lock and hub splines before installation.
3. Start locking hub assembly into hub. Ensure large tangs are lined up with lock washer and outside diameter and inside diameter splines are in line with hub and axle shaft splines.
4. Install retainer ring by closing ring ends with needle-nose pliers and, at the same time, push locking hub assembly into hub. Install seal bridge retainer (narrow end first).
5. Install rubber seal over locking hub. Install locking hub cap assembly. Ensure ball bearing, race, spring and retainer are in proper position. Tighten Torx-R bit screws to 40-50 INCH lbs. (4.5-5.6 N.m) following tightening sequence (tighten 1, skip 1, etc.) until complete.

Removal (F-350 Models)

1. To remove locking hub, first separate locking hub cap assembly from hub body assembly by removing 6 Allen head cap screws from cap assembly, then slip components apart. Detach snap ring (retainer ring) from end of axle shaft.
2. Remove lock ring (seated in groove of wheel hub). (Scheme 19) Slide hub body assembly out of wheel hub. If necessary, use a puller to remove hub body assembly.

Exploded View Of Warn Industries Manual Locking Hub Assembly. Scheme 19

Note. Do not pack grease into locking hub cap. Too much grease can cause excessive dialing effort.

Installation (F-350 Models)

To install locking hub assembly components, reverse removal procedure. Install locking hub cap assembly and tighten cap screws to 35-55 INCH lbs. (4.0-6.2 N.m).

HUB/ROTOR ASSEMBLY, SPINDLE & BEARINGS

Note. Before removing and relubricating front wheel bearings, note which type was used as original wheel bearing lubricant. The recommended wheel and spindle bearing lubricant is a lithium-based grease; Multi-Purpose Long-Life Lubricant C1AZ-19590-B (ESA-M1C75-B).

Removal

1. Raise and support vehicle, then remove wheel and tire assembly. Remove manual or automatic locking hub assemblies. Using Front Wheel Bearing Spanner (T59T-1197-B for F-250 or D78T-1197-A for F-250 H.D. and F-350), detach wheel bearing lock nut, lock ring and adjusting nut.
2. Remove brake caliper and hang with wire away from work area. Do not hang by flexible brake hose. While remove wheel hub/rotor assembly, slide out outer wheel bearing assembly. Pry out inner wheel bearing grease seal and discard.
3. Remove inner bearing. Inspect inner and outer bearings and races. Replace any damaged or excessively worn components. Always replace bearings and races as complete assemblies only. To remove inner and/or outer bearing races from hub, use Slide Hammer (T50T-100-A) and Bearing Race Puller (T77F-1102-A).
4. Detach spindle retaining nuts, then carefully remove spindle from knuckle studs and axle shaft. See STEERING KNUCKLE. Clean any old grease from needle bearings and spindle bore seal. Inspect bearings and seal, then replace if necessary.

Spindle Needle Bearing & Grease Seal Replacement

1. To remove grease seal from top of needle bearing, place spindle in soft-jawed vise (on second step of spindle). Using Slide Hammer (D79P-100-A), Forcing Screw (D80L-100-B) and 1 1/4-1 1/2" Collet (D80L-100-T) from Blind Hole Puller Set (D80L-100-A), remove needle bearing and bearing seal from spindle bore, then discard seal.
2. Install new needle bearing (writing facing outward) in spindle bore using Driver Handle (T80T-4000-W) and Spindle Bearing Installer (T80T-4000-S for F-250 or T80T-4000-R for F-350).
3. Install new needle bearing grease seal (with seal lip directed away from spindle) using Hub Seal Installer (T80T-4000-T for F-250 or T80T-4000-U for F-350) and Driver Handle (T80T-4000-W). Tap in seal until fully seated. Pack bearing and hub seal with grease.

Installation

1. Using multi-purpose lubricant, thoroughly coat spindle needle bearings and pack spindle face in area that mates with spindle bore seal. Assemble spindle, over axle shaft, onto knuckle studs.
2. Tighten spindle-to-knuckle retaining nuts to 20-30 ft. lbs. (27-41 N.m) on F-250 and 50-60 ft. lbs. (68-81 N.m). on F-350. Lubricate wheel bearings with multi-purpose grease.
3. Clean old grease from hub, then apply fresh grease to hub cavity. Install new bearing races if necessary. Thoroughly pack wheel bearings with multi-purpose grease. Install inner wheel bearing and new grease seal.
4. If necessary, clean rotor surface with high-flash point cleaner. Position hub/rotor assembly on spindle, then install outer bearing and adjusting nut. Adjust wheel bearings. Install lock washer, lock nut and locking hub assembly. To complete installation, reverse removal procedure.

1. Insert wrench from rear side of upper shock bracket to hold shock absorber upper retaining nut. Loosen the stud by turning hex provided on exposed (lower) part of stud. Remove nut and washer.
2. Disconnect lower end of shock from "U" bolt spring plate spacer. Compress shock and remove from vehicle. On 1-piece shock mounting grommet, cut grommet from upper shock bracket.

1. Insert a new 1-piece rubber insulator into the top surface of shock bracket using a soap/water solution to aid in installation. Insert shock stud through insulator.
2. Install steel washer and hand tighten nut. While holding nut, turn hex to tighten nut to 25-35 ft. lbs. (34-47 N.m). Attach lower shock mount to "U" bolt plate with mounting bolt and nut, then tighten to 52-74 ft. lbs. (70-100 N.m).

1. Raise and support vehicle, on frame hoist, until weight is off front springs (wheels must still touching floor). Support drive axle assembly (and secure if necessary) to prevent rotation.
2. Disconnect lower end of shock absorber from "U" bolt spring plate spacer. Detach "U" bolt nuts, then remove "U" bolts, "U" bolt spacer and spring plate spacer. Detach nut from leaf spring eye bolt at rear hanger bracket. Drive bolt out of hanger bracket.
3. Detach nut from spring eye bolt at front shackle. Drive out eye bolt from spring and shackle, then remove leaf spring assembly. Detach spring clip, separate spring leafs and check for broken leafs, loss of arc or other damage. Replace components as necessary.

Exploded View Of IFS Front Drive Axle Assembly Always remove lower ball joint first. Scheme 20

1. Position front of leaf spring assembly in front spring shackle, then install eye bolt through spring and shackle. Tighten eye bolt nut to 120-150 ft. lbs. (163-203 N.m).
2. Position rear of spring assembly in rear bracket. Install eye bolt through spring and hanger bracket. Install eye bolt nut and tighten to 120-150 ft. lbs. (163-203 N.m).
3. Position "U" bolt spring plate spacer on top of spring assembly. Position lower spring spacer below spring assembly, then install "U" bolts in saddles on upper plate spacer and through holes in lower spring spacer. Install "U" bolt nuts finger tight.
4. Connect lower end of shock absorber to "U" bolt spring plate spacer bracket and tighten mounting bolt to specification. Lower vehicle and tighten "U" bolt nuts to 85-120 ft. lbs. (115-163 N.m). Remove axle restrains.

Scheme 21

1. Detach spindle retainer nuts. If necessary, tap with soft-faced hammer to break spindle loose from knuckle. Remove spindle, brake rotor splash shield and axle shaft assembly. To remove the upper ball joint, turn "C" clamp forcing screw clockwise and press joint out of knuckle, then assemble installer components and press new joint into bore until firmly seated. (Scheme 21): Upper & Lower Ball Joint Removal Installation
2. If necessary, remove grease seal from top of spindle needle bearing. If tie rod has not been removed, detach cotter pin from stud. Loosen top ball joint stud nut and bottom ball joint stud nut (inside of knuckle). Remove top nut. Sharply hit top stud with soft-faced hammer to free knuckle from axle arm. Remove and discard bottom nut. NOTE: Check orientation of camber adjuster to ensure the same camber setting during assembly.
3. Remove camber adjuster by hand or, if necessary, use Pitman Arm Puller (T64P-3590-F). Place knuckle in vise and remove snap ring from bottom ball joint socket (if equipped). NOTE: Always remove lower ball joint first.
4. Remove plug from "C" Clamp (T74P-4635-C) and replace with Plug (T80T-3010-A4). Assembly "C' clamp and Receiver (D79T-3010-A4 for F-250 or T80T-3010-A2 for F-350) onto bottom ball joint.
5. Turn forcing screw clockwise until ball joint is removed from knuckle. Install "C" clamp and Receiver (D79P-3010-BG) on upper ball joint and turn forcing screw clockwise to remove.

Scheme 22

1. Clean steering knuckle bore and install lower ball joint as straight as possible. On F-250 models, assemble "C" clamp, Ball Joint Receiver Cup (T80T-3010-A3) and Installer Cup (D79T-3010-BF) onto lower joint, then turn forcing screw clockwise until joint is firmly seated. Install snap ring on lower joint (if equipped).
2. On F-350 models, assemble "C" clamp, ball joint receiver cup and Installer Cup (D79T-3010-BG) onto lower joint, then turn forcing screw clockwise until joint is firmly seated. Install snap ring on lower joint (if equipped). NOTE: If either ball joint cannot be installed to the proper depth, realignment of Receiver Cup (T80T-3010-A3) will be necessary.
3. Position upper ball joint in knuckle bore. To install F-250/350 upper joint, assemble "C" clamp, Receiver Cup (T80T-3010-A3) and Ball Joint Replacer (T80T-3010-A1) onto upper joint. then turn forcing screw clockwise until joint is firmly seated. (Scheme 22): Removing & Installing Axle Housing Pivot Bushing
4. Assemble knuckle to axle arm assembly. Install camber adjuster on top ball joint stud with arrow pointing outboard for positive camber or inboard for negative camber. Install new nut on bottom stud finger tight. Install and tighten top stud nut finger tight.
5. Tighten bottom nut to 80 ft. lbs. (109 N.m). Tighten top nut to 100 ft. lbs. (136 N.m). Only tighten top nut to align cotter pin hole, do not back off. Retighten bottom nut to 90-110 ft. lbs. (123-150 N.m).
6. Install new needle bearing (writing facing outward) in spindle bore using Driver Handle (T80T-4000-W) and Spindle Bearing Installer (T80T-4000-S for F-250 or T80T-4000-R for F-350). Install new needle bearing grease seal with seal lip directed away from spindle.
7. Pack bearing and hub seal with grease. Install seal using Seal Installer (T80T-4000-T) and driver handle. Install seal on top of needle bearing. Apply light coat of grease to seal lip. Place thrust washer on axle shaft.
8. Install left hand shaft assembly into differential side gear. Install right hand shaft assembly into slip yoke, giving special attention that wide tooth space in slip yoke spline is aligned with wide tooth on axle shaft spline.
9. Lubricate splines with multi-purpose grease. Install splash shield and spindle. Install and tighten spindle retainer nuts to 50-60 ft. lbs. (68-81 N.m).

AXLE HOUSING ARM ASSEMBLY, PIVOT BRACKET & BUSHING

1. Remove manual or automatic locking hub assembly, hub/rotor assembly, spindle, splash shield and axle shaft assembly. Place supports securely under axle housing arms, then remove pivot bolts. If necessary, pry axle housing arm out of bracket and remove from vehicle.
2. If necessary, raise engine to provide access to vertical bracket fasteners in top of crossmember by loosening right and left engine mounting bolts. Align fan blade to clear shroud and raise engine 2 inches.
3. Ensure air cleaner does not touch firewall. Block engine securely in place. Remove and discard all axle pivot bracket-to-crossmember fasteners, then remove pivot brackets.
4. Install Forcing Screw (T78P-5638-A1), Pivot Bushing Remover (T80T-5638-A1) and Receiver Cup (T78P-5638-A3) onto pivot bushing. Turn forcing screw and remove pivot bushing.

1. Place new pivot bushing in axle housing bore. Install Receiver Cup (T78P-5638-A2), forcing screw and Pivot Bushing Replacer (T80T-5638-A2) onto axle housing. Turn forcing screw to press bushing into bore.
2. Position axle pivot bracket to crossmember and loosely install bolts, bolts/retainer assembly and nuts. Do not tighten at this time. Ensure new vertical fasteners for each pivot bracket are installed with bolt heads adjacent to engine oil pan to maintain required clearance.
3. New horizontal fasteners must be installed with bolt heads on inside surface of pivot brackets. To ensure correct positioning of axle pivot brackets, first tighten horizontal fasteners in side of crossmember to 110 ft. lbs. (149 N.m).
4. Tighten vertical fasteners in top of crossmember to 110 ft. lbs. (149 N.m). Position axle housing in pivot brackets. Install pivot bolt and tighten nut to 150 ft. lbs. (200 N.m). Remove blocks supporting engine and lower engine into position. Install and tighten mount bolts. To complete installation, reverse removal procedure.

1. Raise and support vehicle. Detach bolts, washers and nuts securing links to spring seat caps on both sides. Remove nuts, washers and rubber insulator grommets connecting links to stabilizer bar. Remove link assemblies.
2. Detach nuts and bolts securing stabilizer bar retainer brackets to mounting bracket and remove retainers. Remove stabilizer bar.
3. If necessary, detach stabilizer bar mount bracket mounting bolts and nuts, then remove bracket from frame rails. Inspect insulator bushings, grommets and bar for excessive wear or damage. Replace components as needed.

1. Apply rubber grease to insulator area of bar, then install new insulators onto bar (if split-type insulator, ensure slit is toward front). To install stabilizer bar and components, replace components in reverse of removal procedure (without tightening bolts).
2. Tighten nuts connecting stabilizer bar links to spring seat caps, on both sides, to 48-65 ft. lbs. (65-88 N.m). Tighten nuts connecting links to stabilizer bar to 15-25 ft. lbs. (21-33 N.m). Tighten nuts and bolts connecting retainers to mounting bracket to 25-35 ft. lbs. (34-48 N.m). Lower vehicle.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS