This procedure covers removal and replacement of both upper and lower ball joints on the front suspension of a 2011-2014 Ford F-150 3.5L EcoBoost 4WD.

Warnings

Tools required

Parts

• Upper ball joint (driver side) × 1 — Use OEM specification
• Upper ball joint (passenger side) × 1 — Use OEM specification
• Lower ball joint (driver side) × 1 — Use OEM specification
• Lower ball joint (passenger side) × 1 — Use OEM specification
• Cotter pins (various sizes) × 4 — Per ball joint specifications
• Pinch bolts × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove front wheels completely
5. Apply penetrating oil to all ball joint nuts, pinch bolts, and control arm bolts; allow 15-20 minutes to penetrate
6. Inspect replacement ball joints to ensure correct parts before beginning disassembly

Procedure

1. 1

   Support lower control arm
   Position floor jack under lower control arm close to the ball joint area. Raise jack to slightly compress the coil spring and support suspension load. This relieves tension on upper components and prevents the control arm from dropping suddenly when disconnected.
2. 2

   Disconnect sway bar link
   Locate the sway bar end link connected to the lower control arm. Hold the shaft with an Allen key to prevent rotation, then remove the lower nut. Swing the link upward out of the way and secure with wire or zip tie to prevent interference.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint castle nut using pliers or cotter pin tool. Remove the castle nut completely. Note which torque specification applies based on nut style (75 lb-ft or 86 lb-ft). Keep the nut for reference when installing new components.
   ℹ️Do not reuse cotter pins. Always install new cotter pins during reassembly.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
4. 4

   Separate upper ball joint from knuckle
   Using a ball joint separator tool or approved pickle fork, insert between the knuckle and upper control arm at the ball joint taper. Strike the tool firmly with a hammer or tighten the separator tool screw to break the taper connection. Once loose, remove the tool and lift the upper control arm away from the knuckle.
   ⚠Pickle fork tools will damage ball joint boots. Only use if replacing ball joints.
5. 5

   Remove lower ball joint pinch bolt
   Locate the pinch bolt that secures the lower ball joint stud to the steering knuckle. This is a through-bolt with a nut on the backside. Remove the pinch bolt and nut completely and discard (new bolt required for reassembly). Spread the pinch clamp slightly with a pry bar if necessary to release the ball joint taper.
   ℹ️Pinch bolt is single-use. Do not reuse the original bolt.
   Torque spec

   Pinch Bolt70 Nm (52 lb-ft)
6. 6

   Separate knuckle from lower ball joint
   With the pinch bolt removed, carefully pry or pull the steering knuckle away from the lower ball joint stud. You may need to tap the knuckle with a hammer while prying to break it free. Once separated, support the knuckle and brake assembly with wire or rope from the frame to prevent strain on brake hose and ABS wire.
7. 7

   Remove upper control arm bolts
   With knuckle supported out of the way, access the upper control arm mounting bolts at the frame. Remove both bolts securing the upper control arm to the frame brackets. The control arm can now be removed from the vehicle for ball joint replacement. Mark orientation if desired for reference.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
8. 8

   Press out old upper ball joint
   Using a ball joint press tool with appropriate adapters, press the old upper ball joint out of the control arm. Position the control arm in the press with the ball joint facing downward. Select a receiver cup that fits around the ball joint housing and a driver that contacts only the ball joint body, not the stud. Apply steady pressure until the ball joint releases from the control arm bore.
   ⚠Ensure press adapters are correctly sized and seated to prevent tool slippage under high pressure.
9. 9

   Install new upper ball joint
   Clean the ball joint bore in the control arm with a wire brush. Position the new upper ball joint in the bore with the correct orientation (stud facing downward). Using the ball joint press with appropriate driver and receiver, press the new ball joint into the control arm until fully seated. The ball joint should be flush or at the specified depth per manufacturer instructions.
10. 10

    Press out old lower ball joint
    The lower ball joint is pressed into the lower control arm. If the lower control arm has been removed (two large bolts at frame), use the ball joint press to remove the old lower ball joint. Position adapters to support the control arm around the ball joint bore and press the ball joint downward out of the arm. If control arm remains installed, a specialized in-vehicle ball joint press may be required.
    ℹ️Some technicians prefer to remove the lower control arm for easier ball joint replacement. This adds time but improves access.
11. 11

    Install new lower ball joint
    Clean the lower ball joint bore thoroughly. Position the new lower ball joint with correct orientation and press into the lower control arm using the ball joint press. Ensure the ball joint is fully seated to the bottom of the bore. Verify that any snap ring or retaining feature is properly engaged if equipped.
12. 12

    Reinstall upper control arm
    Position the upper control arm with new ball joint back into the frame brackets. Install both control arm bolts finger-tight only. Do not torque at this time. Ensure the ball joint stud is accessible and properly oriented to engage the steering knuckle.
13. 13

    Connect ball joints to knuckle
    Lower or raise the steering knuckle assembly into position. Insert the lower ball joint stud into the knuckle pinch clamp opening. Install the new pinch bolt and nut, torquing to specification. Insert the upper ball joint stud into the upper knuckle opening. Install the castle nut and torque to specification (verify which specification applies: 75 or 86 lb-ft). Install a new cotter pin through the castle nut and ball joint stud, bending ends to secure.
    Torque spec

    Pinch Bolt70 Nm (52 lb-ft)

    Ball Joint Nut101 Nm (75 lb-ft)
14. 14

    Reconnect sway bar link
    Position the sway bar end link back to the lower control arm mounting point. Install the nut while holding the shaft with an Allen key to prevent rotation. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
15. 15

    Final torque suspension components
    Install wheels and lower the vehicle so full weight is on the suspension (wheels on ground). Final torque the upper control arm bolts to specification with vehicle weight on wheels. This ensures proper bushing alignment and prevents premature wear. Torque wheel lug nuts to specification in a star pattern.
    ⚠Control arm bolts must be torqued with vehicle weight on suspension. Torquing while suspended will preload bushings incorrectly.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Repeat entire procedure for opposite side if replacing both sides
2. Verify all fasteners are torqued to specification and all cotter pins are installed
3. Verify brake hoses and ABS wires are not pinched, twisted, or under tension

Verification

• Test drive vehicle at low speed and verify no unusual noises or vibrations from front suspension
• Perform a visual inspection under the vehicle for any loose components or leaking fluids
• Schedule a professional wheel alignment immediately after ball joint replacement, as suspension geometry has been altered
• Re-torque wheel lug nuts after 50-100 miles of driving

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