Ford F150 Pickup. Instruction — part 1792

Raise and support front of vehicle under lower control arm. Have assistant grasp tire at upper and lower edges.
Move tire in and out with a rocking motion while observing movement between the spindle and the upper and
lower ball joints. Replace lower ball joint if movement exceeds .03" (.79 mm). Replace upper control arm
assembly if movement exceeds .03" (.79 mm).

RIDE HEIGHT

1. Raise vehicle on hoist with frictionless plates to support front wheels. Jounce vehicle to normalize static

ride height. Measure distance between center of lower control arm front bolt and ground (STEP 1 in
illustration). See Fig. 2 . Measure distance between bottom of steering knuckle and ground (STEP 2 in
illustration). Subtract smaller measurement from larger measurement. This value is ride height
measurement.

2. Ride height should be as specified. See RIDE HEIGHT SPECIFICATIONS table. If ride height is not

as specified, tighten or loosen torsion bar adjusting bolt at each side as required. Ensure to check ride
height at each side after each adjustment.

RIDE HEIGHT SPECIFICATIONS

CAUTION: Use hand tools to adjust riding height. DO NOT use power tools.

CAUTION: The torsion bar adjustment bolt is coated with dry Loctite and must

be replaced if it is backed off or removed. Failure to do so can cause
the adjustment bolt to loosen up during operation and a loss of
vehicle alignment.

Application

In. (mm)

Original Components

3.89-5.11 (99-130)

New Components

5.00-5.23 (127-133)

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

Fig. 2: Measuring Front Riding Height

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

Courtesy of FORD MOTOR CO.

WHEEL ALIGNMENT

WHEEL BEARING

Front wheel bearings are permanently sealed and do not require lubrication or adjustment. Hub and bearing is
replaced as an assembly. To inspect, carry out the following steps.

1. Position the vehicle on a hoist. Rotate the hublocks to the locked position. Shift the transfer case to an

engaged position. With the vehicle in Drive, run the vehicle to 25 MPH.

2. Evaluate the front wheel that is turning. Place the stethoscope on the steering knuckle near the wheel

bearing. Make a mental note of the sound. Using the brakes, stop the wheels from turning.

3. Evaluate the other front wheel. While holding the previously evaluated wheel, run the vehicle to 25 MPH.

Place the stethoscope on the knuckle near the wheel bearing. Make a mental note of the sound. Using the
brakes, stop the wheels from turning.

4. Compare the results. If one side sounds significantly louder than the other or both sides sound equally

loud, go to next step. If both sides sound similar (not loud or noisy), the wheel bearings are okay.

Carry out the following steps for the wheel bearing endplay setup.

5. Install the dial indicator gauge with holding fixture (D78P-4201-B), to the steering knuckle. Place the

probe on the brake disc where the splash shield has a "V" opening. Make sure the probe can move in a
lateral direction. Tighten the neck of the probe.

6. Push the wheel inward at the 6 o'clock position. Set the dial indicator to zero. Pull the wheel outward at

the 6 o'clock position. Record the measurement. Repeat this step 3 to 5 times. If the wheel bearing
endplay is greater than 0.005" (0.13 mm), install a new hub and bearing assembly. See HUB &
BEARING ASSEMBLY under REMOVAL & INSTALLATION. If the wheel bearing endplay is less

NOTE:

See SPECIFICATIONS & PROCEDURES article under WHEEL ALIGNMENT in
SUSPENSION.

NOTE:

An assistant will be needed for this procedure.

NOTE:

If the vehicle is equipped with a limited slip front axle, both the wheels will
be turning. Evaluate both wheels at this time.

NOTE:

If the vehicle is equipped with a limited slip front axle, do not hold the
wheel. Evaluate both simultaneously.

NOTE:

Make sure the wheel rotates freely and rotate the hublocks to the unlocked
position.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

than 0.005" (0.13 mm), the wheel bearing is within specification. Go to the next step.

7. Remove the wheel hub. See HUB & BEARING ASSEMBLY under REMOVAL & INSTALLATION.

8. With the wheel hub unit on a bench, rotate the outer flange of the wheel bearing while applying

downward pressure. If the wheel bearing rotates freely, without roughness or noise the wheel bearing is
okay. If the wheel bearing does not rotate freely, or makes noise, install a new hub and bearing assembly.
See HUB & BEARING ASSEMBLY under REMOVAL & INSTALLATION.

REMOVAL & INSTALLATION

HUB & BEARING ASSEMBLY

Removal

1. Raise and support vehicle. Remove wheel assembly. Remove brake caliper. Support caliper aside.

Remove brake caliper anchor. Mark brake rotor and hub, and remove brake rotor. Remove and discard
cotter pin. Remove hub nut retainer and nut. Remove brake rotor shield (if necessary).

2. Remove the Anti-Lock Brake System (ABS) sensor from the steering knuckle (if equipped). Remove hub

and bearing assembly by removing three bolts from rear of steering knuckle. See Fig. 3 . DO NOT over-
extend CV joint. Slide hub and bearing assembly off CV axle shaft splines. Remove steering knuckle
grease seal. Inspect steering knuckle grease seal, hub and bearing assembly for excessive wear and
damage. Replace components as necessary.

Installation

1. Using Bearing Cup Replacer (T80T-4000-P), Knuckle Seal Replacer (T96T-1175-A) and Threaded

Drawbar (T77F-1176-A), install the seal until it seats against steering knuckle. Install hub and bearing
assembly onto steering knuckle, guiding CV axle shaft through spline in hub. Tighten hub and bearing
assembly bolts to specification. See TORQUE SPECIFICATIONS .

2. If equipped with ABS, install the front brake sensor. Align marks, and install brake rotor and caliper.

Tighten hub retainer nut to specification. See TORQUE SPECIFICATIONS . Install washer, nut lock
and NEW cotter pin. DO NOT back off nut to install cotter pin. To complete installation, reverse removal
procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Before
driving vehicle, pump brake pedal several times to restore normal pedal position.

WARNING:

Always remove any corrosion, dirt or foreign material from wheel
mounting surfaces. If wheels are installed without proper metal-to-metal
contact at wheel mounting surfaces, lug nuts can loosen while vehicle is
in motion. Check lug nut torque after 500 miles after wheel installation.

NOTE:

CV joint is a slip fit into wheel hub and bearing assembly and should not
require puller to remove.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup