Have 2006 F250 4wd, i'm replacing the axle seals (at each end of the axle tubes AND behind the hub assembly). I can't get the axles out!
There are no axle retaining clips at the differential. It will only budge about 1/4". I've tried pushing in, then jerking it out. Also tried prying out on the u-joint from the cast iron spindle assembly (yes, the hub assembly is out).

What's the trick? Please don't respond unless you've actually done it yourself. I'm tired of getting advice from guys who've done it on the older trucks and the NAPA parts guys. My two local Ford service guys aren't very helpful either (one told me to pull the diff cover and pull the axle retaining clips off the axles - they aren't there thanks).

Any help is greatly appreciated. I'm at my wit's end!

 

On mine the knuckle seal was keeping the axle from coming out so I had to take a large screwdriver and pound on the seal from the inside and basically destroy the seal to get it and the axle out.

 

Assuming you have everything else removed, the only thing putting up a fight is the big seal.

I had to pry on mine as shown in the pic below to break them free. If prying don't work you'll have to trash that seal like Bagpipes said.

 

BFG and a pry bar...rotate axle and do it again.

PB Blaster in generous amounts.

 

I guess I didn't get mad enough. I beat the heck out of the seal from the inside and drove it out.

Now, installed the new style axle tube seal then installed the axle with the new outer seal assembled.

The axle doesn't seem to be in all the way. I remember seeing the axle protrude inside the differential just about 1/16" before I disassembled it. Now, it's just flush. But when I drive the axle in it bounces when I hit it as if it were bottomed out on something. Any thoughts?

PS What kind of lube does the front diff use?
PPS What grease do you use on the lock outs?

Thanks

 

If I remember right when you bolt the hub on it will push the axle in that little extra.

 

75/140W I think for lube...manual will tell you.

Do not need any friction modifier for the front diff

 

Did you get the knuckle seal installed onto the axle properly? Did you use the knuckle seal driver to seat the axle/seal in the knuckle?

 

No. I used a large washer, socket and extension. I tapped it in as far as it would go. This axle tube seal doesn't appear to be keeping the axle from going all the way in. In fact, it looks like there is more axle shaft showing vs the original axle tube seal assembly.

 

I just replaced mine as well and IIRC it looked weird on mine but I had it seated completely with the driver tool. Remember that with the new dust seal will be tucked into the axle tube a bit further so it will look like there is more axle shaft showing if that makes sense.