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Front Diff & Ball Joints

From 1983 Ford Bronco “That dirty old truck” — documented by Steve83.

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1983 Ford Bronco - At [url=http://www.supermotors.net/registry/2742/71223-4]OCBR09 , I blew the caps off the U-joint in the driver's knuckle, but I didn't hav… 1983 Ford Bronco - Everything up to this point is shown in the [url=http://www.supermotors.net/registry/2742/12739-4]Brakes & Hubs album , so I won't duplicat… 1983 Ford Bronco - Loosen, but don't remove, the lower BJ nut ([url=https://www.amazon.com//dp/B000C5HPRO/]MotorCraft MCS-10253 ). Back it off just until it's… 1983 Ford Bronco - Flip the upper BJ nut and set it flush with the stud. This not only prevents the stud from mushrooming, but also prevents the cotter pin ho… 1983 Ford Bronco - Factory solid Camber Cam ~'90-96 1/2-ton 4WD I now have these to replace them: [url=http://www.supermotors.net/registry/media/843080] http:… 1983 Ford Bronco - 92-96 Camber Cam size Read the NEXT several captions... 1983 Ford Bronco - Once the taper is loose, pry up the camber cam (if installed). The older style has different indexing. This is my new favorite way to pull… 1983 Ford Bronco - The lower BJ ([url=https://www.amazon.com//dp/B000C5HPRO/]MotorCraft MCS-10253 ) had never been removed, so this one was MUCH harder. I bea… 1983 Ford Bronco - Nothing to see here - move along. For another little TTB-specific job, see this: [url=http://www.supermotors.net/vehicles/registry/media/78… 1983 Ford Bronco - This [url=http://buy1.snapon.com/catalog/item.asp?P65=&tool=all&item_ID=75395&group_ID=1631&store=snapon-store&dir=catalog]Snap-On BJ press… 1983 Ford Bronco - Halfway thru, I had to add some washers between the adapters on the ram. Upper BJ: [url=https://www.amazon.com/dp/B000C5HPUG/]MotorCraft MC… 1983 Ford Bronco - Installing the new BJ ([url=https://www.amazon.com/dp/B000C5HPUG/]MotorCraft MCS-10339 ) also took some creativity - IIRC, it's 8 & 7 on th… 1983 Ford Bronco - After putting the knuckle back on, I got down to the REAL problem. For another little TTB-specific job, see this: [url=http://www.supermoto… 1983 Ford Bronco - Do you notice what's missing? 1983 Ford Bronco - THERE it is! Well, at least 1/3 of it... 1983 Ford Bronco - If you don't know your gear ratio, try to get a look at the edge of the ring gear. Some have the ratio, but this one has the tooth counts a… 1983 Ford Bronco - What a mess... I had guessed it was a side gear that shattered, based on the noise it made. I'm seriously considering Lincoln-locking this… 1983 Ford Bronco - The E-ring barely visible on the end of the axleshaft is what makes this job a pain. This time, I just unclamped the boot from the far R sh… 1983 Ford Bronco - I think if I had tried, it would have been easy to remove this C-clip through the fill hole in the front of the axle beam. I might omit it… 1983 Ford Bronco - After beginning to tear it down, I decided to check the backlash. It's within spec. 1983 Ford Bronco - This tool is something I made for fan clutches & pinion nuts, and it works. The big ratchet is also handy. That's my sandblasted-&-clearcoa… 1983 Ford Bronco - Everything is stripped down & cleaned for welding, except for sandblasting inside the carrier. I won't reinstall the pinion shaft or the re… 1983 Ford Bronco - The welds are a little rough, but my welder (my g/f's nephew) just had rotator cuff surgery & his R arm was in a sling. And it's still bett… 1983 Ford Bronco - The E-clip for the right inboard shaft of a Dana 44IFS can be picked through the fill hole. I tried on a D50IFS, but I don't think it's pos… 1983 Ford Bronco - Because the factory E-ring is such a hassle, many people weld the slip yoke cap & install a spring to hold the inner shaft in the diff. But… 1983 Ford Bronco - I straightened & then reset the keystone clamps on the slip yoke boot. 1983 Ford Bronco - To make draining easier & cleaner, I cut a hole in the bottom of the beam below the lowest point of the 3rd member housing. Since I'm using… 1983 Ford Bronco - I started with a 1/4" bit, then 1/2", then 3/4" to make the drain hole in the 3rd member. SEE THE NEXT FEW PICS... [url=http… 1983 Ford Bronco - It took a lot of driving to find this 1/2"-14 NPT tap to match the stock diff plug that I'm going to use. DON'T OVERTAP any pipe-threa… 1983 Ford Bronco - This factory magnetic diff plug should collect any welding spatter that I didn't knock off, and it's flush enough not to interfere with the… 1983 Ford Bronco - All slapped together & ready to go back! I'm putting the slip yoke back onto the outer shaft first, and then stabbing the inner (with my ne… 1983 Ford Bronco - I knew it wouldn't be exactly aligned, so I'll widen the hole with a burr one of these days. [url=https://www.supermotors.net/registry/medi… 1983 Ford Bronco - Well, I THOUGHT my gorilla welds had broken at OCBR, but apparently not... Both hub locks are shattered. [url=https://www.supermotors.net/r… 1983 Ford Bronco - The debris in the splines caught in the outer ring's groove, preventing the lock body from sliding out, so I put the trusty Snap-On slide h… 1983 Ford Bronco - Eventually, most of the sections with threads had pulled out. 1983 Ford Bronco - Fortunately, there was just enough to grab, and it finally came out. [url=https://www.supermotors.net/registry/media/840034] https://www.su… 1983 Ford Bronco - The other side wasn't nearly this bad, but I still had my O'Reilly's receipt from 1999, and they swapped them out again with no hassle. [ur… 1983 Ford Bronco - Installation & Adjustment for (Moog K80108 ) 3 1/4-degree dual-axis camber cams [url=https://www.supermotors.net/registry/media/1170256] ht… 1983 Ford Bronco - Raybestos Ball Joints for most D44IFS TTBs; Ford/MotorCraft are better, and not substantially more expensive. Upper: [url=https://www.amazo… 1983 Ford Bronco - Pressing the upper BJ ([url=https://www.amazon.com/dp/B000C5HPUG/]MotorCraft MCS-10339 ) in first using the big Snap-On press & cups only t… 1983 Ford Bronco - Pressing the lower BJ ([url=https://www.amazon.com/dp/B000C5HPRO/]MotorCraft MCS-10253 ) in last, so it wasn't in the way of pressing the u… 1983 Ford Bronco - Upper Ball Joint: Ford F6TZ3V049AA, MC MCS10339, Spicer 2001257 Lower Ball Joint: Ford F6TZ3V050CB, MC MCS10253 , Spicer 2001258 , TRW JBJ7… 1983 Ford Bronco - Ball Joint Removal with a torch IF THE IMAGE IS TOO SMALL, click it. Ball joint presses are cumbersome, weak, and very slow, requiring a lo… 1983 Ford Bronco - JY '90 F150 Dana44IFS TTB Tag [url=http://www.supermotors.net/registry/media/1046322] http://www.supermotors.net/getfile/1046322/thumbnail/…