This procedure covers the removal and replacement of both front CV axles on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 and 4WD, including front differential fluid drain and refill.

Warnings

Tools required

Parts

• Front CV axle assembly - driver side × 1 — Use OEM or quality aftermarket
• Front CV axle assembly - passenger side × 1 — Use OEM or quality aftermarket
• Front differential drain plug gasket × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Axle nut (if not included with CV axle) × 2 — Use OEM specification
• Cotter pin (if applicable to vehicle) × 2 — Check existing axle nut type

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen (but do not remove) front wheel lug nuts while vehicle is on ground
4. Loosen both front axle nuts 1/4 turn while vehicle is on ground (requires 36mm socket and breaker bar)
5. Raise front of vehicle and support securely on jack stands at frame rails
6. Remove both front wheels completely
7. Spray penetrating oil on ball joint nuts, CV bolts, and differential drain/fill plugs. Allow to soak 10-15 minutes

Procedure

1. 1

   Drain front differential fluid
   Position drain pan under front differential. Locate drain plug on bottom of differential housing. Slowly loosen drain plug with appropriate socket and allow fluid to drain completely. Once drained, remove and inspect drain plug gasket. Clean drain plug threads with wire brush and install new gasket. Reinstall drain plug finger-tight only (will torque after fill).
2. 2

   Remove CV axle-to-differential mounting bolts (driver side)
   Locate the six bolts connecting the CV axle inner joint to the front differential flange. Mark the orientation of the CV axle flange to differential flange with a paint pen or marker. Support the CV axle with one hand or wire to prevent it from dropping. Remove all six CV bolts and carefully pull the inner CV joint away from the differential. Allow any remaining fluid to drain into pan. Hang the axle aside with mechanics wire to prevent damage to the outer joint.
   ℹ️Mark flange orientation before removal to maintain balance when installing new axle.
3. 3

   Separate lower ball joint (driver side)
   Locate the lower ball joint nut connecting the lower control arm to the steering knuckle. Remove the castle nut completely. Use a ball joint separator tool or pickle fork to separate the ball joint taper from the knuckle. Insert tool between control arm and knuckle and strike firmly with hammer until joint releases. Be careful not to damage the ball joint boot if reusing the control arm.
   ⚠Ball joint separator will likely damage the ball joint boot. This is acceptable as you are only separating to remove the axle, not the control arm.
4. 4

   Remove driver side CV axle
   Remove the 36mm axle nut completely from the wheel hub. Pull the steering knuckle outward while pushing the CV axle shaft out of the wheel hub splines. If axle is stuck in hub, use a brass drift and hammer to tap the end of the axle shaft through the hub bearing. Once the outer splines are clear, remove the CV axle assembly completely from the vehicle. Inspect the hub bearing seal for damage.
   ⚠Do not use excessive force on axle shaft threads. If seized in hub, apply penetrating oil and allow to soak before proceeding.
5. 5

   Remove passenger side CV axle
   Repeat steps 2-4 for the passenger side CV axle. Remove the six CV bolts from the differential flange (marking orientation), separate the lower ball joint, remove the axle nut, and extract the complete CV axle assembly from the vehicle. With both axles removed, inspect the differential output seals for leaks or damage.
6. 6

   Prepare new CV axles for installation
   Unpack new CV axles and verify correct parts for left and right sides. Inspect new axles for shipping damage and verify boots are intact. Clean the wheel hub splines with wire brush and apply a light coat of anti-seize compound to the splines (not the threads). Clean the differential flange mounting surfaces with wire brush to remove old threadlocker residue.
   ℹ️Do not apply grease to CV axle splines going into wheel hub. Anti-seize only on splines, keep threads clean and dry.
7. 7

   Install driver side CV axle
   Guide the outer end of the CV axle through the wheel hub, aligning the splines carefully. Thread the new axle nut onto the shaft by hand to hold the axle in position. Do not torque yet. Align the inner CV joint flange with the differential flange using the orientation marks made during removal. Install all six CV bolts with medium-strength threadlocker and hand-tighten only at this stage.
8. 8

   Reconnect driver side lower ball joint
   Pull the steering knuckle downward and align the lower ball joint stud with the hole in the knuckle. Insert the ball joint stud through the knuckle and install the castle nut. Torque the ball joint nut to specification. If using a castle nut with cotter pin, align the castle slots with the cotter pin hole and install new cotter pin. If using a prevailing torque nut, verify it is properly seated.
   ⚠Never loosen ball joint nut to align cotter pin holes. If necessary, tighten further up to 1/6 turn (60 degrees) to align.
   Torque spec

   Ball Joint Nut117 Nm (86 lb-ft)
9. 9

   Torque driver side CV axle fasteners
   Torque the six CV axle-to-differential flange bolts to specification in a crisscross pattern to ensure even seating. Use a pry bar against the brake rotor or have an assistant apply the brakes to prevent the axle from rotating. Torque the 36mm axle nut to specification. Stake the axle nut or install cotter pin per the specific nut design on your vehicle.
   ℹ️Axle nut must be torqued with vehicle weight on suspension or with brakes applied to prevent axle rotation.
   Torque spec

   CV Bolts70 Nm (52 lb-ft)

   Axle Nut250 Nm (184 lb-ft)
10. 10

    Install passenger side CV axle and torque fasteners
    Repeat steps 7-9 for the passenger side CV axle. Install outer end through wheel hub, hand-start axle nut, align inner flange with differential using orientation marks, install six CV bolts with threadlocker, reconnect lower ball joint and torque castle nut, then torque all six CV bolts and the axle nut to specification. Stake axle nut or install cotter pin as required.
    Torque spec

    Ball Joint Nut117 Nm (86 lb-ft)

    CV Bolts70 Nm (52 lb-ft)

    Axle Nut250 Nm (184 lb-ft)
11. 11

    Refill front differential
    Locate the fill plug on the side of the front differential housing. Remove the fill plug and gasket. Using a gear oil pump or fluid transfer pump, add 75W-90 GL-5 gear oil until fluid begins to drain from the fill hole (approximately 1.5 quarts). Allow excess to drain out, then install new fill plug gasket and reinstall fill plug. Clean the drain plug and torque to specification.
    ℹ️Differential is filled to correct level when fluid reaches the bottom of the fill plug hole. Do not overfill.
    Torque spec

    Differential Cover Bolts35 Nm (26 lb-ft)
12. 12

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower vehicle until tires just contact the ground but suspension is not yet loaded. Torque wheel lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands. Torque lug nuts again in star pattern to verify proper seating.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification, especially axle nuts and CV bolts
2. Ensure axle nuts are properly staked or cotter pins are installed and bent
3. Check that CV axle boots are not torn or damaged from installation
4. Verify front differential fluid level is correct and fill plug is installed with new gasket
5. Double-check that both lower ball joints are properly seated and torqued

Verification

• Start engine and verify no unusual noises from front differential or CV axles
• Check underneath vehicle for any gear oil leaks from differential drain or fill plugs
• Test drive vehicle in a safe area, making slow turns in both directions to verify CV axles are functioning properly
• Listen for clicking or popping noises during turns which would indicate improper installation
• Verify no vibration at highway speeds that would indicate imbalanced CV axle installation
• After test drive, re-inspect all fasteners and re-torque if necessary
• Check differential fluid level again after test drive to ensure no leaks have developed

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