Replace both front CV axle shafts on a 4WD Ford F-150 with 5.0L V8, including removal of wheel bearings and disconnection from the front differential.

Warnings

Tools required

Parts

• Front CV axle shaft (driver side) × 1 — Use OEM specification for 4WD 5.0L
• Front CV axle shaft (passenger side) × 1 — Use OEM specification for 4WD 5.0L
• Axle hub nut × 2 — One-time use, purchase new
• Cotter pins or staking hardware × 2 — Per axle nut specification
• Front differential cover gasket × 1 — Reusable RTV or OEM gasket

Fluids

• 75W-90 GL-5 Gear Oil — 1.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground (do not remove)
3. Unstake or remove cotter pin from axle hub nuts, then loosen axle nuts with breaker bar while vehicle is on ground (do not remove completely)
4. Lift front of vehicle and secure on jack stands at frame points
5. Remove front wheels completely
6. Place drain pan under front differential to catch gear oil

Procedure

1. 1

   Remove axle hub nut
   With vehicle raised and wheel removed, completely remove the previously loosened 27mm axle hub nut from the wheel bearing. Discard the nut as it is one-time use.
2. 2

   Separate lower ball joint
   Remove the ball joint castellated nut. Use a pickle fork or ball joint separator tool to separate the lower ball joint from the knuckle. Be careful not to damage the ball joint boot if reusing suspension components.
   ⚠Ball joint separator can damage boots. Use care if reusing components.
   Torque spec

   Ball Joint Nut127 Nm (94 lb-ft)
3. 3

   Disconnect CV axle from differential (driver side)
   Locate the six CV bolts connecting the inner CV joint flange to the differential output flange. Remove all six bolts using an 18mm socket. Support the axle shaft to prevent it from falling.
   ⚠Gear oil will begin draining once axle is disconnected. Position drain pan appropriately.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
4. 4

   Remove driver side CV axle
   Pull the axle shaft outward through the wheel bearing hub while supporting the inner CV joint. Remove the entire assembly from the vehicle. Some wiggling and rotation may be needed to clear the bearing and suspension components.
5. 5

   Disconnect CV axle from differential (passenger side)
   Repeat the CV bolt removal process for the passenger side axle. Remove all six bolts from the inner CV flange-to-differential connection. The passenger side may have slightly different clearance due to differential placement.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
6. 6

   Remove passenger side CV axle
   Pull the passenger side axle shaft outward through the wheel bearing hub while supporting the assembly. Remove completely from vehicle. Allow remaining gear oil to drain into pan.
7. 7

   Clean mounting surfaces
   Clean the differential output flanges with a wire brush to remove old gear oil residue and debris. Clean the wheel bearing hub splines with a clean rag. Inspect the differential output seals for damage or leaking.
8. 8

   Install new driver side CV axle
   Insert the new driver side CV axle through the wheel bearing hub, ensuring the splines fully engage. Guide the inner CV flange to align with the differential output flange. Hand-thread all six CV bolts to hold in position.
9. 9

   Torque driver side CV bolts
   Torque all six CV bolts to specification in a star pattern. Ensure the flange is fully seated before final torquing.
   Torque spec

   CV Bolts76 Nm (56 lb-ft)
10. 10

    Install new passenger side CV axle
    Repeat the installation process for the passenger side. Insert through wheel bearing hub, align inner CV flange with differential output flange, and hand-thread all six CV bolts.
11. 11

    Torque passenger side CV bolts
    Torque all six passenger side CV bolts to specification in a star pattern.
    Torque spec

    CV Bolts76 Nm (56 lb-ft)
12. 12

    Reconnect lower ball joints
    Reconnect both lower ball joints to the steering knuckles. Install the castellated nuts and torque to specification. Install new cotter pins to secure.
    Torque spec

    Ball Joint Nut127 Nm (94 lb-ft)
13. 13

    Install new axle hub nuts
    Thread the new axle hub nuts onto both axle shafts by hand. Do not torque yet as wheels need to be installed and vehicle lowered for final torquing.
14. 14

    Refill front differential
    Using a fluid transfer pump, refill the front differential with 1.5 quarts of 75W-90 GL-5 gear oil through the fill hole. Fill until oil begins to drip from the fill hole, indicating proper level.
15. 15

    Reinstall wheels and final torque
    Reinstall both front wheels and hand-tighten lug nuts. Lower vehicle to the ground. Torque wheel lug nuts to specification in a star pattern. With vehicle on ground and brakes applied, torque both axle hub nuts to specification. Stake the axle nuts or install new cotter pins as per manufacturer specification.
    ⚠Axle nut must be torqued with vehicle weight on suspension and brakes applied to prevent axle rotation.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

    Axle Nut250 Nm (184 lb-ft)

Reassembly

1. Ensure all CV bolts are torqued in star pattern to prevent flange warping
2. Verify axle hub nuts are properly staked or secured with new cotter pins
3. Double-check front differential fluid level after test drive

Verification

• Test drive vehicle and verify no clicking, popping, or vibration from CV axles during turns
• Check for gear oil leaks around differential output seals and CV bolt flanges
• Verify no play in axle shafts by attempting to move wheel in/out with vehicle raised
• Confirm proper 4WD engagement if equipped with electronic or manual hubs

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