Overhaul a Ford Econoline's Front End Steering and Suspension

Worn axle pivot and radius arm bushings can cause wobbling in vehicles, and it is important to know how to replace them. You can also replace ball joints and pack bearings at the same time. Learn how to give a 2" lift to an 1992-2014 Ford E-250/E-350,

Steps

Wheel Removal

1. Park the vehicle on a flat and leveled surface.
   • It is best to work on concrete slab or asphalt floor, where you can lift the vehicle and work on, that is hard enough to keep the jack and jack-stands from sinking or tipping over.
2. Avoid working on sloped or uneven ground.
3. Block the rear tires with blocks on front and back to keep from rolling.
4. Use jack-stands in addition to a jack.
5. Remove lug nuts and remove the wheel.

Removing the Brake Caliper

1. Remove the two brake caliper bolts.
2. Use a 21-millimeter socket, breaker bar, and a ratchet.
3. Support the caliper on a solid surface. Leaving the caliper hanging could damage the brakelines.
4. Don't allow any pressure on the brake lines.
   • The weight of the caliper or bending of the rubber hose could tear or rupture the hydraulic lines.

Removing Rotor and Bearings

1. Remove the brake disk, rotor and bearings.
2. Use the back of a crescent wrench to knock off the dust cover.
3. Remove the cotter pin and the spindle nut retainer.
   • Do this using needle nose pliers.
4. Use the crescent wrench to remove the spindle nut and washer. Then, pull the crescent wrench off the rotor while supporting it with your hands on the front.
   • By doing this, you can make sure the bearing doesn't fall out.

Removing Sensors and Tie Rod

1. Remove the sensor holder and bracket.
   • Use an 8-millimeter socket and ratchet to do so.
2. Using a 15mm socket and ratchet, loosen the bolt for the camber-nut mount.
3. Use needle nose pliers to remove the cotter pin from the tie rod end.
4. Gently tap on the outside edge of the steering knuckle where the tie rod inserts. Do this to knock it loose.

Removing Ball Joint Nut and Steering Knuckle

1. Remove the cotter pin from the ball joint nut. Use needle nose pliers to do so.
2. Remove the lower ball joint nut with a crescent wrench.
3. Widen the camber nut holder with a wedge and a slight tap from a hammer. Then use the hammer and carefully hit the steering knuckle on flat strong areas. This will knock it loose and remove it.
4. Use a Ball Joint Press to Replace Ball Joints. This is a specialized tool that is used only for this application and an unnecessary expense unless you work or own a repair shop,
   • Rent a ball joint press from a local automotive store.
   • Use this to remove and reinstall the upper and lower ball joints.

Removing Radius Arm Bolts, Shocks, and Axle Pivot Bushings

1. Loosen and remove bolts that hold the radius arms to the frame. Use a 15-millimeter socket, breaker bar and ratchet.
2. Using a 11/16" socket and ratchet, remove the bolt holding on the lower portion of the shock to the radius arm.
   • If needed use a pickle fork to pry the shock off.
3. Using a 21mm socket and ratchet backed by a 13/16" wrench to prevent slippage, remove the bolt through the radius arm bushings, at which point the radius arm and I-beam assembly can be removed.
4. Remove spring retainer bar and spring then the shock from upper mount (as pictured below).

Replacing Radius Arm Bushings

1. Remove radius arm nut and replace with Moog K80005 radius arm bushings.

Cleaning and Re-greasing I-Beam Cup and Axle Pivot Bushings

1. Using the ball joint press, press out the center of the axle pivot bushings and leave the cup intact.
2. Use any safe solvents or abrasive methods available and clean out the inside of the cup to remove all rubber bushings and ensure a smooth finish.
3. Install Energy Suspension 4.3121G axle pivot bushings. 

Replacing Shocks and Springs With New Upgrades

1. Install Moog CC80S spring. This is a spring for larger box truck econolines and will give roughly a 2" lift with no major modifications outside of an alignment following installation. 
2. Install longer length Bilstein BE56140T5 shocks to account for the extra ride height, otherwise stock shock will "top out". 
3. Reinstall Radius Arm and I-Beam Assembly.
   • Reverse previous steps and reinstall radius arm and I-beam assembly.

Reinstalling Steering Knuckle, Moog Caster-Camber Nut and Re-greasing Ball Joints

1. Place the steering knuckle back in place.
2. Tighten the knuckle down the lower ball joint nut, then add a cotter pin.
3. Slide in a Moog K80109 caster/camber nut.
4. Tighten down the retaining bolt in a position that has the caster at neutral. The camber should also be near vertical and angled slightly away from the vehicle. 
5. Grease ball joints via the grease inserts. Do this using a Grease pump.

Cleaning, Packing, and Sealing Bearings

1. Clean and Grease Steering Knuckle Spindle, and Reinstall Rotor.
2. Remove the outer wheel bearing.
3. Remove the inner wheel bearing seal. Do this with a screwdriver or pliers and inner wheel bearing.
4. Wipe the bearings down and clean them with a rag.
5. Spin the wheel bearings in cup of unleaded gasoline. Do this until there is no longer material coming off of the bearings and the gasoline is as clear as when you put it in.
6. Dry the bearings and let them sit until completely dry.
7. Pack bearings. Use the widest part to scoop grease through the teeth in the palm of your hand. Do so until it pushes through the top side all the way around.
8. Grease the inside of the rotor where the race is. Do this before replacing the bearing.
9. Reinstall the inner bearing. Using a flat object, gently tap the seal into place with a hammer.
10. Clean and grease the steering knuckle spindle, then slide it on the rotor. Insert the outer bearing and tighten down spindle nut over bearing. Tighten until just before there is no play in the wheel.
11. Attach the nut retainer cup and put a cotter pin through.
12. Attach the tie rods.
13. Install the brake caliper, install the wheel, and get an alignment.

Things You'll Need

• Jack
• Jack Stands
• Ball joint press kit
• Large Socket Kit
• Pickle Fork
• Breaker bar
• Ratchet
• 1mm socket
• mm socket
• 5mm socket
• 11/16 in socket
• Wrench
• Needle nose pliers
• File or small abrasive wheel

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