2009 F250

just found both front axle dust seals poped out of the axle housing on F250 4X4 what would have caused that? wheel bearings going out? what to expect? Thanks Howard

They are just a weak point on those trucks. Ford/Motorcraft has an updated seal that allows more movement and lasts better.
They are not too hard to do:
1) Remove brake caliper, caliper mount, and rotor. I usually just wire the caliper back out of the way.
2) Remove the small bolts holding the lock out hubs in the housing. Slide the lock out assembly out.
3) Reach in and remove the large snap ring that holds the axle into the wheel bearing assembly.
4) Remove the wheel bearing assembly bolts out the inside of the pivot casting.
5) Then remove the wheel bearing assembly out of the casting.
6) Carefully slide the axle and the inner hub seal, out of the casting. Then remove the old seal out of the housing. The new seal is installed in the next outer grove from the original seal. You also need to clean the inner half of the axle up so the new seal will slide on the axle without damaging it.
7) Install the new style seal in the outer grove. This can be tricky as it is a large flat piece of thin steel with the seal towards the center. You can't bend it without ruining the seal. The new seal rotates inside of itself. So if you bend it the seal will not rotate in the correct place. ( I ruined the first one I ever installed)

The just reverse the disassembly and you will be good to go. Doing it this way will not effect the alignment of the front axle. There are a few You Tube videos that show taking the ball joints apart and leaving the outer hub assemble together. This is harder to do and WILL effect the alignment of the truck. Plus you usually will ruin the ball joints doing it that way.

A friend has SIX 2008 Ford F250s I have done this to all of them. It takes me about 4 hours start to finish now. The first one about 6-7 hours not pushing it.