This procedure covers the removal and replacement of a manual locking hub assembly on a 4WD 2011-2014 Ford F-150 3.5L EcoBoost, restoring proper engagement of the front axle.

Warnings

Tools required

Parts

• Manual locking hub assembly × 1 — Use OEM specification or verify aftermarket compatibility
• Hub cover gasket or O-ring × 1 — Usually included with hub assembly
• Axle nut cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is still on ground (do not remove)
4. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified points
5. Remove front wheel completely
6. Ensure transfer case is in 2WD position before beginning work

Procedure

1. 1

   Remove hub cover
   Locate the manual locking hub cover on the front wheel hub assembly. Remove the cover screws (typically 6-8 screws around the perimeter) using appropriate socket or screwdriver. Carefully lift the hub cover away from the hub body. Inspect the cover gasket or O-ring for damage.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
2. 2

   Remove cotter pin and axle nut
   Using pliers, remove and discard the cotter pin from the axle nut. This pin prevents the axle nut from loosening. Use a breaker bar and appropriate socket to loosen the axle nut. The nut is torqued to 250 Nm and will require significant force. Remove the axle nut completely and set aside.
   ⚠The axle nut is under high torque. Ensure the vehicle is securely supported and the socket is fully seated to prevent slipping.
   Torque spec

   Axle Nut250 Nm (184 lb-ft)
3. 3

   Remove locking hub body mounting bolts
   Locate the mounting bolts that secure the locking hub body to the wheel hub (typically 6 bolts in a circular pattern). Remove all mounting bolts and keep them organized. These bolts secure the entire hub assembly to the spindle.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Remove locking hub assembly
   Carefully pull the locking hub assembly straight off the axle shaft and spindle. The assembly may be tight due to the splined connection and corrosion. If stuck, gently tap around the perimeter with a rubber mallet to break it free. Avoid prying, which could damage sealing surfaces.
   ℹ️The hub assembly contains internal springs and small components. Keep the assembly upright to prevent parts from falling out if reusing.
5. 5

   Clean and inspect mounting surfaces
   Use a wire brush and shop towels to thoroughly clean the axle shaft splines, spindle face, and hub mounting surface. Remove all dirt, corrosion, and old gasket material. Inspect the axle shaft splines for wear or damage. Check the wheel bearing for play or roughness by attempting to move the rotor/hub assembly.
   ℹ️If wheel bearing has excessive play or noise, it should be addressed before installing the new locking hub.
6. 6

   Prepare new locking hub assembly
   Remove the new locking hub assembly from packaging and verify it matches the old unit. Ensure the new hub includes a fresh gasket or O-ring. Apply a thin coat of anti-seize compound to the axle shaft splines (avoid getting compound on sealing surfaces). Set the locking hub to the 'FREE' position for installation.
   ℹ️Verify the replacement hub is correct for your F-150 model year and axle configuration before installation.
7. 7

   Install new locking hub assembly
   Align the locking hub assembly with the axle shaft splines and spindle. Carefully slide the hub onto the axle shaft, ensuring proper spline engagement. The hub should seat flush against the spindle face. If resistance is felt, verify proper alignment rather than forcing.
   ⚠Cross-threading or misalignment can damage the hub assembly. Ensure proper seating before installing bolts.
8. 8

   Install mounting bolts
   Insert all mounting bolts through the locking hub body into the spindle. Thread all bolts by hand first to ensure proper alignment. Tighten the mounting bolts in a star pattern to ensure even seating. Torque all mounting bolts to 31 Nm (23 lb-ft) in the star pattern.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Install and torque axle nut
   Thread the axle nut onto the axle shaft by hand until finger tight. Using a torque wrench, tighten the axle nut to 250 Nm (184 lb-ft). Install a new cotter pin through the hole in the axle shaft and bend the ends to secure. If the cotter pin hole does not align, tighten the nut slightly (never loosen) until the next alignment point.
   ⚠Always use a new cotter pin. Never reuse the old pin as it may fail and allow the axle nut to loosen.
   Torque spec

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

    Install hub cover
    Position the new gasket or O-ring on the locking hub cover. Align the hub cover with the locking hub body, ensuring the locking mechanism indicator is properly positioned and visible. Install all cover screws and tighten in a star pattern to 12 Nm (9 lb-ft).
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
11. 11

    Reinstall wheel
    Mount the wheel onto the hub and thread all lug nuts by hand. Lower the vehicle until the tire just contacts the ground (still supported by jack stands). Torque the wheel lug nuts to 140 Nm (103 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands. Perform final torque check on lug nuts.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all mounting bolts and fasteners are properly torqued
2. Ensure cotter pin is properly installed and bent to secure the axle nut
3. Confirm hub cover is seated flush with proper gasket seal
4. Check that locking hub can be manually rotated between LOCK and FREE positions smoothly

Verification

• Rotate the locking hub dial between LOCK and FREE positions several times to verify smooth operation
• Start vehicle and engage 4WD. Drive forward and reverse a short distance to confirm front axle engagement
• Listen for unusual noises from the front hub area during operation in both 2WD and 4WD modes
• Return to 2WD mode and verify the hub can be set to FREE position
• Visually inspect for any fluid leaks around the hub assembly
• Test drive the vehicle at low speed in both 2WD and 4WD to confirm proper operation

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