Tools You'll Likely Need:
* Jack and jack stands (SAFETY FIRST: Always use jack stands, never rely solely on a jack)
* Wheel chocks
* Lug wrench
* Socket set (metric)
* Wrenches (metric)
* Axle nut socket (usually large and specialized)
* Ball joint separator
* Tie rod end separator
* Hammer (possibly a mallet)
* Pry bar
* Penetrating oil (like PB Blaster)
* Torque wrench
* ABS sensor tool (may be needed for removal and installation to avoid damage)
* New front axle assembly
* New ABS sensor
* Grease
* Shop rags or paper towels
Procedure: Replacing the Front Axle Assembly (This is generally done with the ABS sensor replaced simultaneously):
1. Safety First: Engage the parking brake, chock the rear wheels, and use jack stands to securely lift the front of the vehicle.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Disconnect Components:
* Brake Caliper: Disconnect the brake caliper from the caliper bracket using a caliper bracket retaining bolt. Carefully support the caliper with a bungee cord or wire to prevent it from hanging by the brake line.
* ABS Sensor Wire Harness: Disconnect the ABS sensor wire harness connector.
* Tie Rod End: Disconnect the tie rod end from the steering knuckle using a tie rod end separator. Mark the location of the tie rod to ensure accurate reinstallation.
* Brake Line: Carefully disconnect the brake line bracket from the axle. This often requires loosening and slightly adjusting the bracket. Be sure to keep brake fluid spillage to a minimum.
* Ball Joint: Separate the ball joint from the steering knuckle. This usually requires a ball joint separator tool.
4. Remove the Axle: Remove the axle nut. It's usually very tight, so use penetrating oil and a powerful impact wrench if necessary. With the other components disconnected, the axle should now be able to be removed from the knuckle and the hub.
5. Install the New Axle Assembly:
* Install the new axle assembly, reversing the removal process.
* Install the new ABS sensor, making sure the connector is securely plugged. Again, a special tool might be needed to carefully install the sensor without damaging it.
* Tighten all nuts and bolts to the manufacturer's specifications (check your repair manual).
6. Reconnect Components: Reconnect all components, ensuring everything is properly seated and secured.
7. Lower the Vehicle: Carefully lower the vehicle and reinstall the wheel, tightening the lug nuts to the proper torque specification.
8. Bleed the Brakes: After reconnecting the brake lines, you may need to bleed the brakes to remove any air that got into the system.
9. Test Drive and Alignment: Test drive the vehicle carefully and have the wheel alignment checked by a professional to ensure proper tracking and tire wear.
Replacing the ABS Sensor (If doing this separately):
If you're only replacing the ABS sensor, the process is less involved:
1. Follow steps 1 and 2 from the axle replacement procedure.
2. Disconnect the ABS sensor wire harness.
3. Carefully remove the old ABS sensor (some require a special tool to avoid damaging the sensor's wiring).
4. Install the new sensor.
5. Reconnect the wire harness.
6. Reinstall the wheel and lower the vehicle.
7. Check the ABS system using a scan tool.
Important Notes:
* Consult a repair manual: This information is for guidance only. Always consult a repair manual specific to your 2002 Ford Escape for detailed instructions, torque specifications, and diagrams.
* Safety: Work in a safe, well-lit area. Use proper safety equipment, including jack stands.
* Professional Help: If you're not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic. Incorrect installation can lead to serious problems.
This is a complex repair. If you lack experience, consider having a professional mechanic perform this work to avoid potential damage to your vehicle or personal injury. Remember to always prioritize safety!
