Contact between brake caliper and disc brake on Ford f350 possible ujoint problem or ball joints some up and down movement in hub when wheel is removed

1. Loosen front strut upper mount nuts. 2. Raise and support vehicle, then remove front wheel and tire. 3. Remove wheel hub nut. Do not discard wheel hub nut at this time. 4. Remove front brake caliper anchor plate bolts and position brake caliper and anchor plate assembly aside. Support brake caliper and anchor plate assembly using mechanics wire. 5. Remove brake disc screw, then thread a M10 bolt into brake disc removal hole and tighten to press disc off hub. 6. Remove tie rod end nut, then separate tie rod from wheel knuckle. No special tools are required to separate tie rod from front knuckle; use a mallet to loosen joint. 7. Remove stabilizer bar link upper nut. 8. Detach wheel speed sensor harness from strut. 9. Remove wheel speed sensor from wheel knuckle. Position wheel speed sensor aside. 10. Remove lower ball joint nut, using a crowfoot wrench. Use hex-holding feature to prevent stud from turning while removing nut. 11. Push lower control arm downward until ball joint is clear of wheel knuckle. Use care when releasing lower control arm and knuckle into resting position or damage to ball joint seal may occur. 12. Press halfshaft from wheel bearing and hub, using a suitable front wheel hub remover. Support halfshaft in a level position. Do not allow halfshaft to move outboard. Overextension of CV joint may result in separation of internal parts, causing failure of halfshaft. 13. Remove upper strut mount nuts. 14. Remove wheel knuckle and strut and spring as an assembly. 15. Remove strut to wheel knuckle nut and flag-bolt. 16. Separate strut and spring assembly from wheel knuckle. 17. Reverse procedure to install, noting following: a. Wheel hub nut contains a one time locking chemical that is activated by heat created when it is tightened. Install and tighten new wheel hub nut to specification within 5 minutes of starting it on threads. Always install a new wheel hub nut after loosening or when not tightened within specified time or damage to components can occur. b. Torque lower strut bolt to knuckle to 129 ft. lbs. c. Torque lower ball joint to knuckle to 148 ft. lbs. d. Torque wheel speed sensor to knuckle to 133 in. lbs. e. Torque stabilizer bar upper link to 111 ft. lbs. f. Torque previously removed hub nut to 258 ft. lbs; to seat halfshaft. g. Torque new hub nut to 258 ft. lbs. h. Torque upper strut mount nuts to 46 ft. lbs. i. Torque wheel lug nuts to 100 ft. lbs.

cv axle service is covered in the FSM and at alldata.com
need books or ?
you can read the Geo book or the corolla book, same car.

the books and online have lots of photos,sorry, im not doing all that....

1. Remove the wheel cover.
2. Remove the cotter pin, hub nut cap, hub nut and washer.
3. Loosen the wheel nuts.
4. Elevate and safely support the car.
5. Remove the front wheel.
6. Remove the lower control arm to ball joint attaching nuts and bolts.
7. Use a ball joint separator such as GM J-24319-01 or equivalent to remove the tie rod ball joint from the knuckle.
8. Remove the bolts holding the brake caliper bracket to the steering knuckle. Use stiff wire to suspend the caliper out of the way; do not let the caliper hang by its hose. Remove the brake disc.
9. Using a puller such as GM J-25287 or equivalent, push the axle from the hub.

The Prizm axle can be separated from the hub using a brass or plastic hammer. Nova requires the use of the puller.

1. Use a slide hammer and appropriate end fitting (GM J-2619-01 and J 35762 or equivalents) to pull the driveshaft from the transaxle. Remove the shaft from the car.

To install:

1. Install shaft into transaxle. If necessary, use a long brass drift and a hammer to drive the housing ribs onto the inner joint.
2. Install the shaft into the wheel hub.
3. Install the lower control arm to the lower ball joint. Tighten the nuts and bolts to 59 ft. lbs.
4. Install the tie rod end to the steering knuckle and tighten the nut to 36 ft. lbs.
5. Install the brake disc; install the brake caliper and tighten the bolts to 65 ft. lbs.
6. Install the wheel.
7. Install the hub nut and washer.
8. Lower the vehicle to the ground.
9. Tighten the wheel lugs to 76 ft. lbs. Tighten the hub nut to 137 ft. lbs.
10. Install the nut, cap, cotter pin and washer. Install the wheel cover.

the next page covers service of the CV axles.
log in and read.

Hi Douglas, I'm glad to help. My first suggestion is to get to complete shaft. This way you want have any problems later on. It's not that much more expensive and you'll be glad you did. Below is the procedure for replacing them.

FRONT DRIVESHAFTS

REMOVAL

1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Hoisting in the Lubrication And Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
2. Remove the cotter pin and nut lock Hub And Bearing To Stub Axle Retaining Nut from the end of the stub axle.
3. Remove the wheel and tire assembly from the vehicle.
4. Remove the wave washer Wave Washer from the end of the stub axle CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.
   
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut.
6. Remove the two front disc brake caliper to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle Brake Caliper Mounting To Steering Knuckle
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly Correctly Supported Disc Brake Caliper Do not allow the brake caliper assembly to hang by the brake flex hose.
9. Remove the brake rotor from the hub and bearing assembly Remove/Install Brake Rotor
10. Remove nut attaching outer tie rod end to steering knuckle Removing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench.
11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113 Tie Rod End Removal From Steering Knuckle Arm
12. Remove the steering knuckle to ball joint stud, clamping nut and bolt Control Arm To Steering Knuckle Attachment from the steering knuckle.
13. Using a pry bar, separate steering knuckle from ball joint stud Separating Ball Joint Stud From Steering Knuckle Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported.
    
14. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly Steering Knuckle Separation From Driveshaft
15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case Disengaging Inner Tripod Joint From Transaxle Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear.
16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal Tripod Joint Removal from Transaxle When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal.

INSTALLATION

1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand Tripod Joint Removal from Transaxle
3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.
4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle.
5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly Outer C/V Joint Inspection
6. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly Steering Knuckle Separation From Driveshaft
7. Install a new steering knuckle to ball joint clamping bolt and nut Control Arm To Steering Knuckle Attachment Tighten the clamping bolt and nut to a torque of 135 N·m (100 ft. lbs.)
8. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, Removing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 N·m (40 ft. lbs.)
9. Install braking disc on hub and bearing assembly Remove/Install Brake Rotor
10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment Brake Caliper Mounting To Steering Knuckle
11. Install disc brake caliper assembly to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts Tighten the disc brake caliper assembly attaching bolts to a torque of 22 N·m (195 in. lbs.)
12. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut.
13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.)
14. Lower vehicle.
15. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) Torquing Front Stub Axle To Hub Nut
16. Install the spring wave washer on the end of the stub axle.
17. Install the hub nut lock, and a new cotter pin Hub And Bearing To Stub Axle Retaining Nut Wrap cotter pin prongs tightly around the hub nut lock as shown in Hub And Bearing To Stub Axle Retaining Nut
18. Check for correct fluid level in transaxle assembly. Refer to Group 21, Transaxle for the correct fluid level checking procedure for the type of transaxle being checked.
19. Set front toe on vehicle to required specification.

it can be any part of the front suspension or brake system including drive train damage jack up right side and with wheel still on place hands at top and bottom of wheel and push and pull in and out if movement usually a ball joint but ball joints dont give off a grinding noise ===now grab tire at the 9 and 3 position front and back -push and pull if loose possible tie rod damage or steering component damaged this also doesnt give off a grinding noise unless bent into a turning part =====turn wheel and listen and look at cv axle and around brake area if noise remove wheel and now inspect brake caliper ,brakes ,hub and axle for noise these components can give you your grinding noise repair or replace damaged components the other tests performed were for possible damaged parts since wheel was bent inward

1. 
   

1. Item

Part Number Description 1 W706540-S900 Axle-to-wheel hub nut (4x4 only)
Removal Note 2 - Wheel speed sensor harness connector
Removal Note 3 2027 Anchor plate bolt (2 required) 4 - Brake caliper, pads and anchor plate
Removal Note 5 1125 Brake disc 6 1107 Wheel hub-to-wheel knuckle bolts 7 1104 Wheel bearing and hub assembly
Removal Note 8 N642567-S36 Tie-rod end-to-wheel knuckle nut 9 W707254-S427 Lower ball joint-to-wheel knuckle nut 10 W520215-S427 Upper ball joint-to-wheel knuckle nut 11 3K185 Wheel knuckle
Installation Note 12 W710279 Integrated wheel and bolt (3 required)

sounds like you have a bearing going out in the hub. The reason it stops making noise with 4 wheel engaged is having the truck in 4 wheel drives puts power to the front hub. Which gives it more stability. In other words you have power which helps bind and hold the bearings from more extensive travel then with it disengaged. The other possibility is you have a ball joint going out. If you are capable of inspection on these to possibilities you will need to jack it up and inspect ball joints for movement and look for abnormal up and down movement of the hub. If not take your truck in and get the front end inspected at a brake or an alignment shop.

check the axle nut and the wheel bearing for play.the caliper bracket is mounted to the hub.the ball joint moves the top of the hub,but movement in the bearing is more likely the cause.

Hub and Bearing Assembly
CAUTION: Do not begin this removal procedure unless the following parts are available:

• A new front axle wheel hub retainer (3B477) (Step 1).
• A new inboard halfshaft joint stub shaft circlip.

Once removed, these parts must not be reused during assembly. Their torque holding ability or retention capability is diminished during removal.
Removal

1. Turn ignition switch to the OFF position and place the steering column in the unlock position.
   

1. CAUTION: Discard the front axle wheel hub retainer. It is a torque prevailing design and cannot be reused. If loosened, the retainer must be removed and a new one installed.
   Remove and discard front axle wheel hub retainer (3B477).
   

1. Raise vehicle on hoist.
   

1. NOTE: Make sure steering column is in the unlocked position, and do not use a hammer to separate tie rod end (3A130) from the front wheel knuckle (3K185) . Use extreme care not to damage boot seal.
   
   Remove cotter pin from tie rod end stud and remove slotted nut. Discard cotter pin and nut.
   

1. Using Tie Rod End Remover 211-001 (TOOL-3290-D) or equivalent and Tie Rod End Remover Adapter 211-087 (T81P-3504-W), remove tie rod end from front wheel knuckle.
   

1. CAUTION: Use extreme care not to damage boot seal. Do not use power tools to remove the nut, or bearing and seal damage will result. Loosen the nut first, then remove nut from stud using the hex hold feature.
   For SHO vehicles, remove vinyl cover from upper link stud.
   Remove stabilizer bar link (5K484) from front shock absorber (18124) .
   

1. Remove disc brake caliper (2B120) and support with wire to obtain working space. Do not allow disc brake caliper to separate from the front disc brake caliper anchor plate (2B292) to prevent contamination of the disc brake guide pin journals. Do not allow disc brake caliper to hang from front brake hose (2078) . Remove front disc brake rotor (1125) . Remove front disc brake rotor from wheel hub (1104) by pulling it off the lug bolt (1107). If front disc brake rotor is difficult to remove from front wheel knuckle , strike front disc brake rotor sharply between lug bolt with a rubber or plastic hammer.
   If front disc brake rotor will not pull off, apply Rust Penetrant and Inhibitor D7AZ-19A501-AA or equivalent meeting Ford specification ESR-M99C56-A to inboard and outboard rotor/hub mating surfaces. Install 3-Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove front disc brake rotor by pulling on front disc brake rotor outside diameter and pushing on hub center. If excessive force is required for removal, check front disc brake rotor for lateral runout prior to installation. Refer to Section 06-00.
   

1. Remove anti-lock brake sensor mounting bolt and front brake anti-lock sensor (2C204) .
   

1. Remove and discard lower ball joint nut. Using Remover Adapter 211-211 (T96P-3010-A1), separate lower ball joint from front suspension lower arm (3078) .
   

1. Using Rotunda Spring Compressor 014-00781 or equivalent, compress front coil spring (5310) until lower ball joint clears front suspension lower arm .
   

1. Using Front Hub Remover/Replacer 204-069 (T81P-1104-C), Two Stud Adapter 205-237 (T86P-1104-A1), Metric Hub Remover Adapter 204-085 (T83P-1104-BH) and Front Hub Installer 204-067 (T81P-1104-A), press front wheel driveshaft joint (3B414) from wheel hub . Wire front wheel driveshaft joint to body to maintain a level position.
   
   
   
   
   
   Item Part Number Description 1 204-085 (T83P-1104-BH) Metric Hub Remover Adapter 2 204-067 (T81P-1104-A) Front Hub Replacer 3 — Turn Wrench Counterclockwise 4 — Hold Wrench Stationary While Turning Other Wrench 5 204-069 (T81P-1104-C) Front Hub Remover/Replacer 6 204-067 (T81P-1104-A)1 Two Stud Adapter A — Make Sure Metric Hub Remover Adapter 204-085 (T83P-1104-BH) is Fully Threaded onto 1107 and is Positioned Opposite the Two Stud Adapter 205-237 (T86P-1104-A1)

1. Remove and discard three hub and bearing retainer bolts from front wheel knuckle .
   

1. NOTE: Wheel hub is not pressed into front wheel knuckle . Do not use slide hammer to remove a stuck wheel hub . Do not strike back of inner bearing race. Use of these methods will damage bearing internal parts.
   
   NOTE: If bearing carrier is corroded to front wheel knuckle , apply Rust Penetrant and Inhibitor D7AZ-19A501-AA or equivalent meeting Ford specification ESR-M99C56-A to the inboard and outboard wheel hub/knuckle mating surface and allow to soak.
   
   Remove wheel hub from front wheel knuckle .
   
   
   
   
   

Installation

1. NOTE: If wheel hub is damaged or if any end play is detectable, replace wheel hub . End play is not adjustable. If wheel hub is disassembled, the assembly must be replaced.
   
   Remove all foreign material from knuckle bearing bore for correct seating of new wheel hub.
   

1. Lightly lubricate mating surfaces of bearing corner and front wheel knuckle.
   

1. CAUTION: Knuckle bore must be clean enough to allow wheel hub to be completely seated by hand. Do not press or draw wheel hub into place.
   Position wheel hub in front wheel knuckle . Install three new hub and bearing retaining bolts. Tighten to 83-107 Nm (61-78 lb-ft).
   

1. Push front wheel driveshaft joint into wheel hub . Hand start front wheel hub retainer.
   

1. Slowly release Rotunda Spring Compressor 014-00781 or equivalent while guiding lower ball joint into front suspension lower arm .
   

1. Install new lower ball joint nut. Tighten to 68-92 Nm (50-67 lb-ft).
   

1. Install tie rod end into front wheel knuckle . Install new slotted nut and tighten to 47-63 Nm (35-46 lb-ft). If necessary advance nut to install a new cotter pin.
   

1. CAUTION: Use extreme care not to damage boot seal. Do not use power tools to tighten nut or bearing and seal damage will result. Install nut using hex hold feature to prevent the stud from rotating.
   Install stabilizer bar link to front shock absorber . Install stabilizer bar link nut. Tighten to 77-103 Nm (57-75 lb-ft). For SHO vehicles, install stud cover.
   

1. NOTE: Remove rust from the rotor and hub mating surfaces with a medium abrasive pad.
   
   Install front disc brake rotor and disc brake caliper . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
   

1. CAUTION: The front axle wheel hub retainer must be tightened to specification immediately during installation. If the retainer is not tightened immediately, the nylon lock will set incorrectly, leading to incorrect torque readings and bearing failure. Any front wheel hub retainer that is not immediately tightened to specification or is loosened must be removed and a new retainer installed.
   Install front axle wheel hub retainer . Tighten to 230-275 Nm (170-203 lb-ft).
   

1. Install wheel and tire. Tighten lug nuts (1012) to 115-142 Nm (85-104 lb-ft).
   

1. Lower vehicle.
   

1. Pump brake pedal prior to moving vehicle to position brake linings.
   

If this is a 2005 F-150 4x4. Usually if there is movement up and down, itmight possibly be the lower ball joints and not the wheel bearing, to verify that it is indeed bearing play you can grab a hold of your tire (with tire of the ground) and try and move it side to side instead of up and down. If you can still feel the movement then it is the wheel bearing. To get to the wheelbearing you will first have to remove the tiny center dust cap in the middle of the wheel. There should be a 13mm bolt you will need to remove under that cap. Next you will have to remove the brake caliper and caliper bridge, then remove the brake rotor. On the backside of the knuckle assembly you will see 4 bolts that hold the hub assembly (your wheel bearing) on. There also may be a plastic ring around the back of the hub assembly too that has vacuum lines running to it for the vacuum hub,this will be held on by 4 or so 8mm bolts, once all these bolts and the4 bolts holding the actuall hub assembly on are removed, you should be able to remove the hub (bearing) assembly from the front of the knuckle assy. Hope this helps.