Replacing Axle Pivot Bushings

If you’re maintaining or rebuilding a 1983-1997 Ford Ranger 4×4, knowing how to properly remove and replace the pivot bushings in your front TTB axle beams is essential. This guide walks you step-by-step through the process on Dana 28, Dana 35, Dana 44, and Dana 50 front axles, showing the correct tools and techniques to avoid damaging your axle or bushings. With clear photos and tips from real-world experience, even a first-time DIYer can successfully complete this repair.

In this tutorial, you’ll learn:

• How to safely remove old pivot bushings from your front axle beams
• Techniques for installing new bushings using a ball joint tool or press
• Common mistakes to avoid, including driving out bushings from the wrong side
• Step-by-step instructions with photos for Dana 28, 35, 44, and 50 TTB axles

This guide is ideal for Ford Ranger and Bronco II 4×4 owners performing front axle maintenance or a rebuild. For more detailed information about your specific axle, see our Dana 28 / 35 TTB Axles guide and Dana 28 & 35 Rebuild tutorial.

Introduction

This article shows you how to properly remove and replace the pivot bushings in your 1983-1997 Ford Ranger 4×4 front axle beams, covering both the Dana 28 and Dana 35 TTB axles. Whether you’re a first-time DIYer or a seasoned Ford enthusiast, the step-by-step instructions and photos make the process straightforward and easy to follow.

Removing The Bushings

Replacing the axle pivot bushings on the Ford TTB axle beam can be a real chore for some people. Some people even think the only way to get it out is to burn it out with a torch. It really isn’t that difficult.

These photos show doing it to a Dana 28 from a 4×4 Ford Ranger / Bronco II, but the same idea will work on the Dana 35 TTB, Dana 44 TTB, and Dana 50 TTB.

On the backside of the beam, you will see where the bushing goes through the beam and mushrooms out a little.

Drive in that edge with a punch or chisel.

Note that there isn’t any solid surface on the back of the bushing to hammer it through. You can try, but the rubber will absorb all of the force.

Once you have the back edge of the bushing driven in, use a chisel to get behind the lip on the front side of the bushing, and then drive it out.

With a little patience, it should come right out.

Installing New Bushings

Now you can install the new bushing:

Use a ball joint maintenance tool (unless you have a press) to install the new bushing through the front of the axle beam.

And you’re done.

DON’T DO THIS:

Don’t try to drive the bushing out of the front of the beam without first doing the backside as described above.

If you do, this is what you’ll end up with. It’s beat to heck and not budging. You can go back and do the backside, but there is little surface to try and push the bushing through. You can’t beat on it with a hammer, because the rubber will just absorb all of the impact.

Related Articles

Dana 28 / 35 TTB Axles (1983-1997)

Dana 28 & 35 Rebuild

Dana 28 to Dana 35 Swap