This procedure covers the removal and replacement of the front driveshaft on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including disconnection from the transfer case and front differential.

Warnings

Tools required

Parts

• Front driveshaft assembly × 1 — Use OEM specification
• Front differential drain plug gasket/washer × 1 — Use OEM specification
• Front differential fill plug gasket/washer × 1 — Use OEM specification
• U-joint strap bolts (if corroded) × 4 — Use OEM specification

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Mark front wheels for reinstallation in original position if removing wheels
3. Raise vehicle and support securely on jack stands at frame rails - minimum 18 inches of clearance needed
4. Remove front skid plate if equipped
5. Place drain pan under front differential

Procedure

1. 1

   Mark driveshaft alignment
   Using marking paint or chalk, mark the relationship between the front driveshaft and the transfer case yoke, and between the driveshaft and the front differential flange. Make clear alignment marks that will be visible during reinstallation. This is critical for maintaining proper driveshaft phasing.
2. 2

   Support the driveshaft
   Position a transmission jack or use wire to support the center of the driveshaft. The driveshaft weighs approximately 15-20 pounds and must be supported to prevent it from falling when disconnected.
3. 3

   Remove transfer case end connection
   Locate the two U-joint strap bolts connecting the front driveshaft to the transfer case output yoke. Remove the two bolts securing the U-joint straps. Carefully pry the U-joint caps away from the yoke using a flat blade screwdriver if necessary. Support the driveshaft to prevent it from dropping.
4. 4

   Drain front differential (partial)
   Position drain pan directly under the front differential. Remove the differential drain plug and allow approximately half the fluid to drain. This reduces spillage when the driveshaft is removed. If time permits, drain completely for fresh fluid change. Remove and inspect drain plug gasket/washer.
   ⚠Gear oil may be hot if vehicle was recently driven. Allow cooling time if necessary.
5. 5

   Remove front differential end connection
   Locate the CV joint or companion flange at the front differential. Remove the bolts securing the front driveshaft CV joint to the front differential flange. There are typically 6 bolts in a circular pattern. Keep bolts organized for reinstallation.
   ⚠Additional differential fluid will drain when driveshaft is separated. Keep drain pan in position.
6. 6

   Remove front driveshaft
   Carefully lower the driveshaft from the vehicle, sliding it away from the front differential first, then separating it from the transfer case yoke. Avoid dropping the driveshaft as this can damage U-joints or CV joints. Inspect the removed driveshaft for worn U-joints, damaged CV boots, or bent tubing.
7. 7

   Inspect and clean mounting surfaces
   Inspect the transfer case output yoke and front differential flange for damage, wear, or excessive runout. Clean all mounting surfaces with a wire brush and shop rags. Remove any corrosion or debris from bolt holes. Check that the differential drain plug is reinstalled if completely drained.
8. 8

   Position new or replacement driveshaft
   Lift the replacement or serviced driveshaft into position. First align the transfer case end, positioning the U-joint caps into the transfer case yoke while aligning your reference marks. Support the driveshaft weight with a transmission jack or helper.
9. 9

   Install transfer case U-joint straps
   Install the U-joint straps over the U-joint caps at the transfer case end. Install the two retaining bolts finger-tight, ensuring the straps are properly seated. Verify alignment marks match before tightening. Torque the U-joint strap bolts evenly to specification.
   ⚠Tighten U-joint strap bolts evenly in a cross pattern to prevent cap binding.
10. 10

    Connect front differential end
    Align the CV joint or companion flange with the front differential flange, matching your alignment marks. Install all CV bolts finger-tight first, then torque in a star pattern to specification. Ensure the CV joint is fully seated against the differential flange.
11. 11

    Refill front differential
    Locate the front differential fill plug on the front or side of the differential housing. Remove the fill plug and gasket/washer. Using a gear oil pump, fill the differential with 75W-90 GL-5 gear oil until it begins to seep from the fill hole (approximately 1.5 quarts). Install new fill plug gasket/washer and reinstall fill plug.
    ℹ️Fill differential until fluid reaches the bottom of the fill plug hole, indicating proper level.
12. 12

    Reinstall skid plate and lower vehicle
    If front skid plate was removed, reinstall it using the appropriate mounting hardware. Carefully lower the vehicle from jack stands. Remove jack stands and lower vehicle completely to the ground.

Reassembly

1. Ensure all alignment marks are properly matched to prevent driveline vibration
2. Verify all fasteners are torqued to specification, especially U-joint straps and CV bolts
3. Check transfer case fluid level through fill plug - top off if necessary with Motorcraft Transfer Case Fluid
4. Wipe down any spilled gear oil from suspension components and frame

Verification

• Start engine and shift transfer case through all ranges (2H, 4H, 4L) to verify operation
• Test drive vehicle at various speeds to check for vibration or unusual noises
• Listen for clunking during acceleration and deceleration that would indicate loose connections
• After test drive, recheck all fastener torque values and inspect for any fluid leaks at differential
• Check front differential and transfer case fluid levels after test drive - top off if needed

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