Ball Joint - Lower

Replace the lower ball joint on a 2005 Dodge Viper, requiring removal of the wheel, separation of the ball joint from the steering knuckle, and pressing out/in the new joint.

Warnings

Tools required

Parts

• Lower ball joint × 1 — Mopar 68003705AA or equivalent
• Cotter pin (castle nut) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle and support securely on jack stands placed on proper frame jacking points
4. Remove wheel and tire assembly completely
5. Spray ball joint stud nut and castle nut with penetrating oil and allow to soak for 10-15 minutes if corrosion is present

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the arm's weight. Raise jack just enough to take up slack but not lift the vehicle. This prevents the control arm from dropping suddenly when the ball joint is disconnected and protects the brake hoses and suspension components from damage.
2. 2

   Remove ball joint castle nut
   Use needle-nose pliers to straighten and remove the cotter pin from the ball joint castle nut. Discard the old cotter pin. Using a socket and breaker bar, remove the castle nut from the lower ball joint stud. Keep the nut for reference when installing the replacement ball joint.
3. 3

   Separate ball joint from knuckle
   Install a ball joint separator tool (pickle fork or forked separator) between the lower control arm and steering knuckle at the ball joint taper. Strike the separator tool with a hammer to break the taper fit. Alternatively, use a ball joint puller tool tightened against the knuckle to press the stud out. Once the taper is broken, remove the separator tool and verify the ball joint stud is free from the knuckle.
   ⚠Use of a pickle fork will damage the ball joint boot. This method is acceptable only when replacing the ball joint.
4. 4

   Remove lower control arm (if required)
   If the ball joint cannot be pressed out with the control arm installed, remove the control arm mounting bolts from the frame. Note the orientation and position of any alignment shims or cams for reinstallation. Mark bolt positions if necessary. Lower the control arm from the vehicle for bench pressing of the ball joint. Refer to control arm removal procedures if additional clearance is needed.
   ℹ️Some ball joint press kits allow in-vehicle pressing. Verify clearance before deciding to remove control arm.
5. 5

   Press out old ball joint
   Using a ball joint press kit or C-clamp with appropriate adapters, position the receiving cup on the lower side of the control arm to catch the ball joint. Position the press screw and driving adapter on top of the ball joint. Tighten the press slowly and evenly to drive the ball joint out of the control arm bore. Remove the old ball joint and inspect the control arm bore for damage, scoring, or deformation.
   ⚠Ensure press adapters are properly aligned to prevent damage to control arm bore. Misalignment can crack or deform the housing.
6. 6

   Clean control arm bore
   Use a wire brush to thoroughly clean the ball joint bore in the control arm, removing all rust, debris, and old material. Inspect the bore for cracks or damage that would prevent proper seating of the new ball joint. The bore surface should be smooth and uniform to ensure proper press-fit of the replacement joint.
7. 7

   Press in new ball joint
   Position the new lower ball joint into the control arm bore, ensuring it is oriented correctly with the stud facing the proper direction (toward knuckle mounting position). Using the ball joint press kit with appropriate adapters, press the new ball joint into the control arm bore until it is fully seated. The ball joint should sit flush or seat to the depth specified by the control arm casting. Verify the joint does not rotate in the bore after installation.
   ⚠Do not strike the ball joint with a hammer. Use only a press tool to avoid damaging the internal components.
8. 8

   Reinstall lower control arm (if removed)
   If the control arm was removed in Step 4, position it back into the mounting location with the ball joint stud pointing toward the steering knuckle. Install the control arm mounting bolts with any alignment shims or cams in their original positions. Hand-tighten the bolts but do not torque at this time—final torquing must be done with vehicle weight on suspension.
9. 9

   Connect ball joint to steering knuckle
   Raise or lower the floor jack under the control arm to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and start the castle nut by hand. Use a socket and torque wrench to tighten the castle nut to specification. Align the castle nut slots with the hole in the ball joint stud (tighten further if needed to align, never loosen). Install a new cotter pin through the stud and bend the ends to secure.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
10. 10

    Remove support jack and reinstall wheel
    Lower and remove the floor jack from under the control arm. Install the wheel and tire assembly onto the hub. Thread all lug nuts by hand, then tighten in a star pattern with a torque wrench to specification.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)
11. 11

    Lower vehicle and final torque control arm
    Lower the vehicle until full weight is on the suspension (tires on ground). If the control arm mounting bolts were loosened or removed, torque them to specification now with the suspension at normal ride height. This ensures proper bushing preload and prevents premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Reassembly is covered in the procedure steps above
2. Always install a new cotter pin—never reuse the old pin
3. Control arm mounting bolts must be torqued with vehicle weight on wheels to prevent bushing bind

Verification

• Verify castle nut is properly torqued and cotter pin is installed and bent to prevent loosening
• Check that ball joint stud moves freely in socket with no binding when steering is turned lock-to-lock (engine off)
• Visually inspect ball joint boot for proper seating and no tears or damage
• Test drive vehicle at low speed and verify no clunking noises from front suspension
• Have front end alignment checked and adjusted as ball joint replacement affects camber and caster settings

More procedures for this vehicle