Tools you'll need:
16mm socket
31mm socket
15mm socket
T30 bit
Hammer
Screwdriver
Some type of seal installer or larger socket in order to install the seals.
A seal remover to remove old seals. That, or some kind of picking / pulling tool to remove the seal.

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Okay, first off, remove the tire. Then use a 16mm socket to remove the upper ball joint bolt and use a hammer to tap the upper control arm + ball joint out of the spindle. Next. Take the caliper off and zip tie it up.
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Push the axle shaft in towards the differential and with a little wiggling, you can get it past the spindle.

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There are two different sizes of front axle seals. The smaller one (ford PN 5L8Z-4B416-AA) goes on the drivers side. Remove the old seal with a seal puller, slide hammer, or a screwdriver and hammer. I used a slide hammer/puller as it was much quicker than a hammer and screwdriver. Do NOT scratch the surface where the seal is "pressed" in, as it may cause leaks. This is why my old seal was leaking. The rubber seal itself was detached from the metal housing, it's supposed to look like the one below. The new seal can be installed using a very large socket, which I don't have. So I cut up a pipe that fit perfectly and used the slide hammer to tap it in.



Be sure to clean the surface where the seal is being pressed in. Also, if you wish you can put a little rtv on the seal flange to prevent leaks. Process is the same for the passenger side. The passenger side seal PN is F57Z-3254-AA

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Torque specs: Ball joint spindle nut+ bolt, 41 lb/ft Caliper bolts: 25 lb/ft Spindle nut: 162 lb/ft
Front driveshaft universal joint to pinion bolts 24 lb/ft.

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Remove the front driveshaft using the T30 socket to remove the universal joint cap bolts.

Remove the front pinion nut. Be sure to index the nut with a marker so you can reinstall it in the same position.



Once you remove the nut, the pinion flange should just pull right out with your hands. Once the flange is removed, use a seal puller or a screwdriver and a hammer to remove the old seal.





Clean the seal surface.



Here is the old seal and the new one. Looks like ford updated the design with a cupped portion added on to the seal, along with a larger rubber "dust boot" that sticks out.





Install the new seal with a seal installer or a piece of pipe like I did.



Install the pinion flange and nut, and be sure to install the flange and nut to where you had indexed it with a marker. It is VERY IMPORTANT that you index the flange and nut, as this puts the proper pressure on the pinion and pinion bearings.



Install the universal joint bolts.

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Nice job, I replaced my front pinion seal and the pinion nut was too tight to remove with hand tools. I had to use the impact gun and then it came right out.

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Slightly improved
4.0 5 speed manual, 31 spline torsen, skid plates, brush guard, LT265/75/16, Explorer OHC and more

Yeah I had too as well. Was a bitch to get off.

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Know this is kinda old now but best thread I can find on the subject. My truck is in the driveway right now for 2 days cause I can not get the bloody seal to seat(axle shaft one) I do not have a socket that big which would need to be around 2 3/4 just got over the passenger side seal and they are costly in that size. So far haven't found a pipe big enough, recall what size you used? Did you have a hard time seating it?
I got my seal from rockauto made by national and I almost want to think its off a bit for how hard its being but the old one did not want to come out and is a bit mangled.
Any help would be grateful!

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Yellow 2001 Ford Ranger Edge 4x4 Ext. cab, 4.0 Automatic, Rancho Shocks, OHC w/buggman leds, mustang dome, Pioneer AVH-X4700BS, Hertz components up front,Rockford fosgate in the rear doors,Sony XM-GS400 4ch Amp, Sony XM-GS-100 Mono Amp. Line-x

Savage03 - I'm about to attempt this within the next few weeks and it's the passenger side as well. How did you overcome this? What diameter size object did you use to seat the axle seal, or what did you use in general? I'd like to have this before pulling apart the front end.

Thanks!

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2003 Ford Ranger XLT, 4.0L, Extended Cab, 4x4, 5-Speed Manual

Well after a week I gave up and 3 seals later I had the last one in enough to get it to a mechanic who charged me $100 to replace the passenger and pinion seal. Really good price. He said it wasn't easy either but he used a large socket like 3/4" drive.
I will never try this again. Doesn't help laying on your back trying to do this lol. So.much easier I'm sure on a lift.
Good luck!

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Yellow 2001 Ford Ranger Edge 4x4 Ext. cab, 4.0 Automatic, Rancho Shocks, OHC w/buggman leds, mustang dome, Pioneer AVH-X4700BS, Hertz components up front,Rockford fosgate in the rear doors,Sony XM-GS400 4ch Amp, Sony XM-GS-100 Mono Amp. Line-x

EEkkk!!! Yikes, this doesn't sound promising haha!! 3/4 doesn't seem big enough? Oh my. I suppose I could buy the seal and walk around Lowes until I find something to fit that diameter

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2003 Ford Ranger XLT, 4.0L, Extended Cab, 4x4, 5-Speed Manual

A good seal driver set is a wonderful thing to have. They are pretty cheap too

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Is this something I can rent from AutoZone or another autoparts store? I'm trying to do my lower ball joint on the driver side and I'm already contemplating buying the press for that... this is getting expensive!!

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2003 Ford Ranger XLT, 4.0L, Extended Cab, 4x4, 5-Speed Manual

Yep but.....⤵⤵⤵

I bought that set also, just one thing it wont work on these seals...
Their is a rubber lip that sticks out, try to use those and you will damage it.
You need something in the range of 2" socket if I recall and that size socket you have to look at 3/4" drive stuff and its not cheap for one socket, around $100 find some used ones on ebay however cheaper if you can wait. I tried all sorts of stuff like a pvc pipe lol, found a axle socket but it wasn't round and it started to bend...was not a fun time.
Yea that last pic is a new seal 1 of 2 I damaged trying to do this. Some reason I did get the smaller driver side one in rather easy, I went ahead and went all in and wanted both sides and the pinion to be done and axles and hubs.

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Yellow 2001 Ford Ranger Edge 4x4 Ext. cab, 4.0 Automatic, Rancho Shocks, OHC w/buggman leds, mustang dome, Pioneer AVH-X4700BS, Hertz components up front,Rockford fosgate in the rear doors,Sony XM-GS400 4ch Amp, Sony XM-GS-100 Mono Amp. Line-x