2002 Ford F-250 Balljoints

LOWER BALL JOINTS
REMOVAL:
With the vehicle in Neutral, position it on a hoist.
Remove the wheel and tire assembly.
Remove and discard the cotter pin. Remove the retainer. Remove the hub nut.

WARNING
Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support.

Remove the caliper support bracket bolts, then position the caliper support bracket and caliper aside.
Remove the brake disc.
Disconnect the front anti-lock brake sensor (ABS) wire assembly.
Remove the tie-rod castellated nut. Discard the cotter pin and nut.

WARNING
Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. Do not damage the tie-rod boot when installing the special tool.

Using the special tool, separate the tie-rod end from the front wheel knuckle.
Using a suitable jack, support the front suspension lower arm.
Remove the lower ball joint castellated nut. Discard the cotter pin. Discard the castellated nut.
Separate the front wheel knuckle from the suspension lower arm. Then, loosely install the castellated nut.
Remove the upper ball joint castellated nut. Discard the cotter pin. Discard the castellated nut.
Separate the front wheel knuckle from the front suspension upper arm.
Separate the halfshaft from the hub, then remove the hand-tightened lower ball joint castellated nut. Remove the front wheel knuckle. Position the halfshaft aside and support with wire.
Remove the snapring from the ball joint. Discard the snapring.
Using a suitable ball joint remover tool and receiver cup, remove the ball joint.

NOTE
Do not damage the ball joint boot when installing the special tool.

NOTE
Clean and inspect the control arm ball joint bore for damage before installing a new ball joint.

NOTE
Make sure the new ball joint snapring is fully seated.

INSTALLATION:
To install, reverse the removal procedure. Always install new castellated nuts and cotter pins. Observe the following torques:
Upper ball joint nut: 66 ft. Lbs. (90 Nm).
Lower ball joint nut: 98 ft. Lbs. (133 Nm).
Tie rod end nut: 70 ft. Lbs. (95 Nm).
Brake caliper support bracket: 136 ft. Lbs. (185 Nm).
Hub nut: 221 ft. Lbs. (300 Nm).

UPPER BALL JOINTS
The upper ball joints are not replaceable and are serviced with the control arm.

REMOVAL:
Raise and support the vehicle.
Remove the wheel and tire assembly.
Remove the front brake disc.
Remove the wheel hub and bearing.
Using a drift, drive the axle shaft main seal out of the wheel knuckle.
Remove the axle shaft and main seal.
Remove the tie-rod end castellated nut.
Disconnect the tie-rod end from the wheel knuckle.
Remove the upper ball joint castellated nut and the insert.
Remove the lower ball joint nut.
Remove the knuckle.
Clean and inspect the wheel knuckle ball joint bores.
Place the wheel knuckle into a suitable vise.

NOTE
Always remove the lower ball joint first.

Remove the lower ball joint.
Using a suitable ball joint press, remove the upper ball joint.

INSTALLATION:
Clean the wheel knuckle ball joint bores.
Using a suitable ball joint press, install the upper ball joint.
Install the lower ball joint.
Install the wheel knuckle.
Position the wheel knuckle onto the axle housing.
Install the nut onto the lower ball joint. Do not tighten the nut at this time.
Install the insert and the castellated nut onto the upper ball joint. Do not tighten the nut at this time.
Tighten the lower ball joint retaining nut. Pre-tighten the nut to 47 Nm (35 ft. Lbs.). NOTE
Do not loosen the castellated nut to install the cotter pin.
Tighten the upper ball joint castellated nut. Torque to 69 ft. Lbs. (94 Nm).
Install the cotter pin. If necessary, tighten the castellated nut until the cotter pin can be installed.
Tighten the lower ball joint nut to 204 Nm (150 ft. Lbs.).
Position the tie-rod end into the wheel knuckle.
Install and tighten the castellated nut. Torque to 52 ft. Lbs. (70 Nm).
Install the cotter pin.
Position the main seal onto the axle shaft.
Using the special tools and a hammer, seat the main seal onto the axle shaft.
Position the axle shaft into the axle housing.
Using the special tools and a hammer, install the main seal into the wheel knuckle
Install the wheel hub and bearing.
Install the front brake disc.
Install the wheel and tire assembly

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