I recently bought a used 1999 Expedition 4WD with 150,000 miles. The pads were shot, rotor was beyond shot, and the front hub bearings are shot. I had no problem removing the caliper assembly but the rotor was rusted on to the hub. I found the nut/bolt trick on YouTube and used that to free the rotor. But now I'm stuck trying to remove the hub assembly. Everything has been soaking in PB Blaster for days and I still broke a 5 ton 3-jaw puller trying to pull the hub. I just got ahold of a 7 ton 2-jaw puller and tried cranking on that but only bent the hub a bit with no success. Help! I've never had so much trouble removing a hub before. I've read the threads on replacing the Expedition/Navigator/F150 hubs, and still can't seem to make any progress. Thank you in advance for ANY help!!

 

Here's the info from my manual;


SECTION 204-01B: Front Suspension — 4x4 2000 Expedition/Navigator Workshop Manual

REMOVAL AND INSTALLATION

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Wheel Hub

Special Tool(s) Bearing Cup Replacer
205-147 (T80T-4000-P)
Knuckle Seal Replacer
205-361 (T96T-1175-A)
Threaded Drawbar
204-029 (T77F-1176-A)

Removal

NOTE: The wheel bearing and hub are installed as an assembly.

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle. For additional information, refer to Section 100-02 .
CAUTION: Do not use heat to loosen a seized wheel nut. Heat can damage the wheel and wheel bearings.

Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .
Remove the brake disc (1125). For additional information, refer to Section 206-03 .
Remove the front wheel hub nut.
Remove and discard the cotter pin.
Remove the retainer.
Remove the nut.

Remove the brake disc shield (2K004).
Remove the bolts.
Remove the brake disc shield.

Remove the front brake anti-lock sensor (2C204).
Remove the bolt.
Remove the front brake anti-lock sensor.

CAUTION: Do not over-extend the CV joint and boots when removing the hub and bearing assembly.

NOTE: The CV joint is a slip fit into the wheel hub and bearing. A puller will not normally be required.

Remove the wheel hub (1104).
Remove the bolts.
Push the CV joint inboard. Remove the wheel hub.

Remove the seal.

Installation

Install the seal using the Knuckle Seal Replacer, the Threaded Drawbar and Bearing Cup Replacer.

Install the wheel hub.
Position the wheel hub on the front wheel driveshaft and joint (3B436) and into the front wheel knuckle (3K185).
Install the wheel hub bolts.

Install the front brake anti-lock sensor.
Install the front brake anti-lock sensor into the wheel hub.
Install the front brake anti-lock sensor bolt.

Install the brake disc shield and front axle hub nut.
Position the brake disc shield.
Install the bolts.
Install the front axle hub nut.
Install the retainer.
Install a new cotter pin.

Install the brake disc. For additional information, refer to Section 206-03 .
WARNING: When the wheel is installed, always remove any corrosion, dirt or foreign material that may be present on the mounting surfaces of the wheels or the surfaces of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without proper metal-to-metal contact at the wheel mounting surfaces can cause the wheel nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.

WARNING: Retighten at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened.

WARNING: Failure to retighten wheel nuts at the mileage specified could allow wheels to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision.

Install the tire and wheel assembly. For additional information, refer to Section 204-04 .
NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.

Lower the vehicle.