Here's a general outline of the process. Specifics may vary slightly depending on your axle configuration (solid or independent rear suspension):
1. Preparation and Safety:
* Safety First: Disconnect the negative battery terminal. Use jack stands to securely support the vehicle. Never work under a vehicle supported only by a jack. Wear safety glasses.
* Gather Tools: You'll need a socket wrench (likely 1/2" drive), the correct size sockets for the axle nut and the axle stud (often 9/16" or ½"), a hammer, a punch (slightly smaller than the axle stud), penetrating oil (like PB Blaster), a torque wrench, new axle studs, and possibly a wheel bearing packer if you disturb the bearing.
* Wheel Removal: Remove the wheel and tire from the affected side.
2. Removing the Old Stud:
* Access: You'll need to access the axle flange. This often involves removing the brake drum (if drum brakes) or caliper (if disc brakes). Consult a repair manual specific to your Expedition for the exact procedure for your brake type.
* Penetrating Oil: Apply penetrating oil liberally to the axle nut and around the axle stud. Let it sit for at least 15-20 minutes to help loosen things up.
* Removing the Axle Nut: Unscrew the axle nut using a socket wrench. It will likely be very tight.
* Stud Removal: Using the punch and hammer, gently tap the old axle stud out from the back of the axle flange. Use firm, consistent taps; avoid damaging the axle flange. If it's stubborn, use more penetrating oil and possibly heat (carefully, to avoid damaging the axle).
3. Installing the New Stud:
* Cleanliness: Clean the axle flange hole thoroughly to remove any debris or rust.
* Lubrication: Lightly lubricate the new axle stud with grease.
* Installation: Carefully tap the new axle stud into the hole using the hammer and punch. Make sure it seats flush with the axle flange. Don't force it; if it's difficult, recheck for obstructions.
* Torque Spec: Once the stud is installed, install the axle nut and tighten it to the manufacturer's specified torque. You can find this specification in your vehicle's repair manual or online. Use a torque wrench to ensure proper tightening—over-tightening can damage the axle.
4. Reassembly:
* Reinstall Brake Components: Reinstall the brake caliper or drum, ensuring proper alignment and function.
* Reinstall Wheel and Tire: Replace the wheel and tire, tightening the lug nuts to the manufacturer's specified torque.
* Check: Before driving, carefully inspect your work to ensure everything is securely fastened.
Crucial Considerations:
* Repair Manual: A factory service manual specific to your 1997 Ford Expedition is highly recommended. This will provide detailed instructions and torque specifications, vital for the success and safety of this repair.
* Axle Nut Torque: Incorrect tightening of the axle nut can lead to wheel bearing damage or axle failure. Use a torque wrench and follow the manufacturer's specifications precisely.
* Wheel Bearing: If you remove the wheel bearing, you'll likely need a wheel bearing packer to properly repack the bearings with grease.
* Professional Help: If you are uncomfortable with any part of this process, consult a qualified mechanic. This is a critical repair affecting the safety of your vehicle.
Remember, this is a general guide. Always consult a repair manual specific to your vehicle for detailed instructions and torque specifications. Improper repair can lead to serious injury or damage.
