35mm axle nut on my '03. I'll have the passenger side done today. (new hub/shocks/lower BJ/new tie rod end) Depending on your miles, you may want to consider your lower BJ's as well while you have all of this apart.

I'll PM you my # if you want ...in case you need anything when you start /dive into this project. Not too bad, just a real PITA on these trucks.

 

Thanks for the help and advice guys. The service manual came in very handy as did the tips from jj. I replaced hub bearing assembly (timken), outer tie rod and lower ball joint (both with moog). Shocks are a month old. I had no luck with the mallet trick trying to remove upper ball joint. I used the large outer tie rod removal tool (borrowed from autozone) which did the trick. The lower ball joint wouldn't budge so I just cut it with a reciprocating saw and pulled off the knuckle. I borrowed a ball joint removal kit from AAP which made easy work of pressing the ball joint out of the lower control arm. It's easy to do with the knuckle removed.

 

I had a time with my lower ball joints. Couldnt get em out with a ball joint press. Took em to a machine shop and they got em out quick. It was worth $10 each!

I used a tie rod removal tool to break loose the ball joints. It clamps down as you screw down so it ends up working well. It took me an hour banging and wrenching on the one side and that thing took less than a minute to pop that taper. Worth having!