This procedure covers the removal and replacement of the front CV axle assembly on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD.

Warnings

Tools required

Parts

• Front CV axle assembly (driver or passenger side specific) × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification
• Cotter pin (if applicable to axle nut type) × 1 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil (front differential) — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen axle nut while vehicle is still on ground (nut is very tight and requires vehicle weight to prevent hub rotation)
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise vehicle and support securely on jack stands at frame rails
5. Remove wheel and tire assembly
6. Place drain pan under front differential to catch gear oil during CV axle removal

Procedure

1. 1

   Remove axle nut
   With vehicle raised and wheel removed, completely remove the 35mm or 36mm axle nut from the end of the CV axle shaft. If nut was previously staked, use a punch to unstake before removal. Discard the old nut if staking points are damaged.
2. 2

   Disconnect lower ball joint
   Remove the ball joint pinch bolt using a 15mm socket. If your vehicle is equipped with a ball joint nut instead of a pinch bolt, remove the nut using a 21mm socket. Once fastener is removed, use a ball joint separator or pickle fork to separate the lower control arm from the steering knuckle. Swing the lower control arm downward to create clearance.
   Torque spec

   Ball Joint Nut117 Nm (86 lb-ft)

   Ball Joint Pinch Bolt55 Nm (41 lb-ft)
3. 3

   Support CV axle
   Support the outer end of the CV axle shaft to prevent it from dropping and damaging the boot or joint once separated from the hub. Use wire or have an assistant hold the axle.
4. 4

   Remove CV axle from wheel hub
   Push the CV axle shaft out of the wheel hub and bearing assembly. If the shaft is stuck in the hub, use a brass drift and hammer to tap it free from the backside, or use a hub puller if necessary. Do not damage the ABS sensor or tone ring during removal.
5. 5

   Remove inner CV joint bolts
   Locate the six bolts securing the inner CV joint to the front differential flange. Remove all six bolts using a 13mm socket. You may need to rotate the differential by turning the opposite side wheel to access all bolts. Support the CV axle as differential fluid will begin to drain.
   ⚠Front differential fluid will drain from this connection. Ensure drain pan is positioned correctly.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
6. 6

   Remove CV axle assembly
   Carefully pull the inner CV joint away from the differential flange and remove the entire CV axle assembly from the vehicle. Keep the axle level during removal to minimize fluid loss. Plug the differential opening with a clean rag or plug to prevent excessive fluid drainage and contamination.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the differential flange mating surface, wheel hub splines, and ball joint taper. Inspect the hub bearing for any roughness or play. Check differential flange bolts for damage and replace if necessary.
8. 8

   Install new CV axle
   Remove the plug from the differential. Align the new CV axle inner joint with the differential flange. Insert the splined outer end of the CV axle into the wheel hub, ensuring it is fully seated. The axle shaft should slide completely into the hub splines.
9. 9

   Install inner CV joint bolts
   Install all six CV joint bolts finger-tight, rotating the differential as needed to access all bolt locations. Once all bolts are started, torque them to specification in a star pattern to ensure even seating of the flange.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)
10. 10

    Reconnect lower ball joint
    Position the lower control arm ball joint into the steering knuckle. Install the ball joint pinch bolt or nut (depending on your specific configuration) and torque to specification. Ensure the ball joint is fully seated in the knuckle taper before tightening.
    Torque spec

    Ball Joint Nut117 Nm (86 lb-ft)

    Ball Joint Pinch Bolt55 Nm (41 lb-ft)
11. 11

    Install and torque axle nut
    Install the new axle nut onto the CV axle shaft threads. Initially torque the axle nut to specification. After torquing, stake the nut by using a punch and hammer to deform the collar of the nut into the axle shaft groove. If your axle uses a cotter pin instead of staking, install a new cotter pin and bend the ends.
    ℹ️Axle nut must be staked or pinned to prevent loosening during operation. Verify proper staking by checking that nut cannot rotate.
    Torque spec

    Axle Nut281 Nm (207 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern but do not fully torque yet. Lower the vehicle until the tire contacts the ground but jack stands still support most of the weight. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
13. 13

    Check and refill front differential fluid
    Locate the front differential fill plug. Remove the fill plug and check fluid level. Add 75W-90 GL-5 gear oil until fluid begins to drip from the fill hole, indicating proper level. Reinstall fill plug. Typically 0.25-0.5 quarts is needed to replace fluid lost during CV axle replacement.

Reassembly

1. Torque all fasteners to specification using a calibrated torque wrench
2. Verify axle nut is properly staked or pinned to prevent loosening
3. Ensure no tools or parts are left in the wheel well before test driving

Verification

• Test drive vehicle at low speed and verify no clicking, popping, or grinding noises from the CV axle during turns
• Check for vibration at highway speeds which could indicate improperly seated axle or hub bearing damage
• Re-check front differential fluid level after test drive and top off if necessary
• Inspect CV axle boots for proper seating and no tears or damage
• Verify no fluid leaks from differential flange or CV joint connection
• Re-torque wheel lug nuts after 50-100 miles of driving

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