I have some clunking and roaring in the front end when the hubs are locked, and I'm doing 40-50 MPH. Not bad, but enough to notice if you're paying attention. I'm thinking the roaring is bearings, and the clunking (while turning, hubs locked, in 2wd) is probably a U-joint. It also makes a pop sound when I take off quickly in first gear, and then pops "back" if I do the same in reverse. No idea what that is. Maybe a ball joint somewhere?

The truck being nearly 20 years old and having 160k miles probably is ready for some new ball joints, tie rod ends, and bearings. Also going to replace the brake pads while I'm in there and have everything apart. Truck has Warn manual hubs, so I figure they are okay.

I don't have the tools to setup a ring and pinion, so I don't want to go that far with it. It probably needs a U-joint or two, and I have no idea how to pull the axle shafts, so this will just focus on the hubs and steering. Although, I would like to put a drain plug on the diff at some point, and I may get the U joints if it's not too hard to pull the axles.

Here's my parts list from Rockauto:



Did I forget anything? I'm not so hot with the terminology of the TTB and all of its inners and outers... I'll need to get a hub socket. Will I need to get a jaw puller to get the lock washers out of the hub?

I found this picture on the intarwebs and was using it and the one below while building my parts list.

 

clunking kind of sounds like u-joints, but not hearing personally, kind of tough to say. as for a puller for the bearings, on my 94 and my 95 i was able to do it with just screwdrivers really. and one specialty socket to pull them all off. its a 30mm or so with 4 prongs at every 90 degrees. thats to pull the hubs all apart for that big nut with a cotter pin in it. make sure you have the right grease for it too.

 

While your in there you may want to replace the seals at the end of the axles. Also seal # 1175 and bearing # 3423. Your that far into it. I ordered mine from Ford. I had the front rebuilt on my F250 and he didn't pull the axles to replace the outer joints. The snap rings were so bad he torched them out. Also how do your rotors look? Might need replaced as well. I know it's an extra step but I replaced all my drive shaft u-joints as well.

 

Id replace the inner spindle bearing and seal while I was there. The heat shields might be trash from rust...they are expensive, some guys run without them but Id replace if needed.

 

Next time I have to do my u joints, I'm doing this

Last set you would ever need.

 

lmfao!!! $2k for axle shafts?

 

Just so I never have to do them again?
I do waste money on fruitless things....

 

Your money, your preference. To be honest, it seems like an awful lot of money.