Hey All, tried doing a search, but couldn't find an answer. Truck is a 2005 Excursion with a Dana 50, so same as mid-year 2003 and earlier F250. Posted here as I figured more people to help.

My right front axle tube dust seal had popped out, so I tore everything down to get the axle shaft (long side) out to replace both the hub vacuum seal and the outer tube dust seal.

I put the axle shaft back in and it felt like everything was good. Before doing the final seating of the hub seal with the special tool, I wanted to confirm that the end splines from the axle had properly seated with the splines inside the pumpkin. I turned the front wheel driveshaft by hand and watched the knuckles at the wheels. The left side knuckle spun as I turned the driveshaft with no issues, but the right side knuckle, the one I was working on, would not move.

I pulled it out a bit and tried re-seating the splines several times. I got it to move ever so slightly once or twice when I turned the front driveshaft by hand, but it basically just stops turning after slight movement. I even tried putting a small block of wood on the knuckle and let the axle shaft ride on that as I slid it in to make sure it was clearing the inner pumpkin oil seal and going in fairly level.

The splines look good and aren't chewed up, so at this point I am stuck. I don't want to put it all back together and just have to rip it apart again, so I don't want to seat the seals

Both left and right knuckles should turn when I spin the drive shaft by hand, correct???

Any help appreciated!!

 

You may be running into an issue with the open front differential not turning the right axle shaft because it is providing more resistance than the left axle shaft. With such low power and speed going into the differential from turning the driveshaft by hand, even a very small difference in resistance from one side to the other will cause the side with lower resistance to spin while the higher resistance side stays stationary. If you put a tool through the u-joint on the left side axle shaft to prevent it from spinning, then spin the front driveshaft, that should cause the right side axle shaft to spin. Alternately, you may be able to lock the hub on the left side and then spin the left wheel , which should cause the right axle shaft to rotate in the opposite direction.

 

Thank goodness you are right! Had someone hold the left knuckle and the right one spun right up. Thank you!!!

 

You are welcome.

 

Those aren't knuckles - they're axleshaft yokes.

Your knuckle attaches to your BALL JOINTS which attach to your "inner C's" or inner knuckles which are welded to your axle tube.

DO NOT worry about the inner splines engaging- if they have not you'll NEVER get everything back together.

If anything you want to be sure the stub shaft has been drawn close to the knuckle and spindle upon reassembly or your steering will BIND as the knuckle and front axleshaft u-joints must rotate (turn) in relatively the same axis. This is the reason for a snap ring on the stub shaft of older 4x4 axles with lockouts (locking hubs)....to keep the entire axle assy from floating in and preventing steering (no steering is bad, mmmmmkay)