Here's a general procedure. However, consult a repair manual specific to your vehicle year and model for detailed instructions and torque specifications. These instructions are a guideline, and variations may exist.
1. Preparation:
* Safety First: Disconnect the negative battery terminal. Secure the truck on jack stands. Never work under a vehicle supported only by a jack.
* Gather Tools: You'll need a socket set (including deep sockets), a wrench set, a pry bar, a hammer, a ball joint separator (or pickle fork, but a separator is less damaging), possibly a C-clamp, a transmission jack (recommended but not strictly necessary), and potentially a gear oil pump and drain pan. A shop manual with diagrams is highly recommended.
* Drain the Differential: This is crucial to prevent gear oil mess. Locate the differential drain plug (usually on the bottom of the differential housing), carefully remove it, and let the oil drain completely into a suitable container.
2. Removal:
* Remove the Wheel and Brake Components: Remove the right front wheel. Disconnect the brake caliper and support it out of the way to prevent damage to the brake line. You might need to remove the cotter pin and castle nut to remove the caliper.
* Disconnect the Axle Shaft:
* ABS Sensor (if equipped): Carefully disconnect the ABS sensor wire from the axle shaft if your truck has anti-lock brakes.
* Inner Axle Nut: Locate the large nut on the inner end of the axle shaft (inside the differential). This is usually a very tight nut – you'll need a good socket and breaker bar, and possibly an impact wrench. Remove this nut carefully.
* Remove the Axle Shaft Retaining Clip: Most 1992 F-150 differentials have a retaining clip (C-clip) holding the axle shaft in place. This is usually located on the inside of the differential, near the differential housing. You'll need to access this either by partially removing the differential cover (recommended approach, see below) or using special long-nose pliers to reach it through the differential housing's opening. *Be careful not to damage the clip.*
* Remove the Axle Shaft: Once the clip is removed, you may be able to gently tap the axle shaft out from the differential housing. If it's stuck, a slide hammer, carefully used, can help. A pry bar can also be used, but be extremely cautious not to damage the differential housing.
3. Differential Cover Removal (Recommended Approach to Access C-Clip):
* Remove the Differential Cover: Locate the differential cover bolts and carefully remove them. The gear oil should already be drained, but there will still be some residual oil, so have rags ready. Remove the cover. This will provide much better access to the axle shaft retaining clip.
4. Installation (Reverse Order):
Installation is the reverse of removal. Ensure the axle shaft retaining clip is properly seated. Torque specifications for the inner axle nut are critical; use your repair manual for the correct torque value. Refill the differential with the correct type and amount of gear oil.
Important Considerations:
* Stub Axle: Be aware that the stub axle (the part of the shaft that sticks out of the differential) might have a different configuration than what you expect. Review your repair manual beforehand.
* Difficulty: This job can be challenging, especially removing the inner axle nut and the retaining clip. If you're not comfortable with this type of repair, it's advisable to take your vehicle to a qualified mechanic.
* Repair Manual: I strongly recommend obtaining a repair manual specific to your 1992 Ford F-150. It will provide detailed instructions, torque specifications, and diagrams that are essential for a successful repair. This information is crucial to avoid damage to your vehicle.
This detailed explanation should help you, but remember, always prioritize safety and consult a repair manual. Improperly done, this repair can lead to damage to your differential or other components.
