You need to pry the axle out now. Usually I use a big pry bar in between the axle, where the U-joint is, and the housing. Sometimes they take a lot of effort to get them out.
To install the new seal you'll need a special seal driver. I'm not sure who else besides your dealer's shop will have that. You need it first to install the seal onto the axle and then to install the seal/axle into the knuckle.
Clean out the knuckle really well before you install it all again. I use a ball hone to clean it out if it's rusty.
so does the drive shaft have to come out of the outer axle tube (towards me as looking at the first photo in thread)? Do I have to open up the diff case ? The housing is still attached to the steering rods and ball joints.
Should all this be off the truck as I dont see how the u joints can pass through the knuckle -
I have been following the page on the dieselstop.com (ball joint replacement), to help me replace the passenger side main seal on the front axle of my 200 F250 SD V10 6.8L. I followed it word for word. However on reaching the end of the job I find the axle on that side is very difficult to rotate, I can barely turn it at all by hand. Rotating the drive shaft by hand causes the divers side axle to turn quite freely but the passenger side stays still (I have the stock diff). Any thoughts ?
(I took the axle to my local Ford on Saturday to fit the new seal and the nice man fitted it for free. He even said I could have just borrowed the tool, taken it home and done it myself if I had wanted. Great guys !)