This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including disconnecting the hub, brake components, steering linkage, and suspension components.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM specification
• Axle hub nut × 1 — One-time use fastener
• Lower ball joint castle nut × 1 — One-time use with cotter pin
• Cotter pin for ball joint × 1 — Standard size
• Brake caliper mounting bolts × 2 — Use OEM specification if corroded

Preparation

1. Park vehicle on level ground and set parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. With vehicle on ground and parking brake applied, break loose the front axle hub nut using a breaker bar and appropriate socket
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheel completely
6. Spray all fasteners to be removed with penetrating oil and allow to soak

Procedure

1. 1

   Remove axle hub nut and ABS sensor
   Completely remove the front axle hub nut that was loosened during preparation. Disconnect the ABS wheel speed sensor electrical connector and remove the sensor mounting bolt. Carefully pull the ABS sensor from the knuckle and secure it out of the way.
2. 2

   Remove brake caliper
   Remove the two brake caliper mounting bolts from the back of the caliper bracket. Slide the caliper off the rotor and support it using a wire hanger or caliper hanger from the strut spring. Do not let the caliper hang by the brake hose.
   ⚠Do not allow brake caliper to hang unsupported by the flexible brake hose as this can cause internal hose damage.
3. 3

   Remove brake rotor and dust shield
   Remove the brake rotor by pulling it straight off the hub. If stuck, use penetrating oil and light hammer taps on the back face. Remove the brake dust shield mounting bolts and remove the shield from the knuckle.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Disconnect outer tie rod end
   Remove the castle nut from the outer tie rod end at the steering knuckle. Use a tie rod end puller to separate the tie rod end from the knuckle arm. Do not use a pickle fork as this will damage the boot.
   ⚠Using a pickle fork on the tie rod end will damage the dust boot and require tie rod end replacement.
5. 5

   Disconnect sway bar link
   Locate the sway bar end link connection at the lower control arm. Hold the center shaft with an Allen key to prevent spinning and remove the upper nut connecting the link to the lower control arm. Swing the link out of the way.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
6. 6

   Remove strut-to-knuckle bolts
   Support the lower control arm with a floor jack to prevent the suspension from dropping. Remove the two large bolts connecting the strut assembly to the steering knuckle. These are pinch-style bolts that clamp the knuckle to the strut.
   ⚠Support the lower control arm before removing strut bolts to prevent sudden suspension drop.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
7. 7

   Separate lower ball joint
   Remove the cotter pin and castle nut from the lower ball joint stud at the bottom of the knuckle. Use a ball joint separator or pickle fork to separate the ball joint stud from the knuckle. Apply force while striking the knuckle boss with a hammer to help release the taper.
   ⚠Ball joint may release suddenly when pressure is applied. Keep hands clear of pinch points.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
8. 8

   Remove knuckle and hub assembly
   With all connections separated, pull the knuckle assembly outward and off the CV axle spline. If the axle is tight in the hub, use a brass drift from the back side to tap it free. Remove the knuckle assembly from the vehicle.
9. 9

   Transfer components to new knuckle
   If installing a bare knuckle, transfer the wheel hub assembly, dust shield, and any other required components from the old knuckle to the new one. Clean all mounting surfaces with a wire brush and apply anti-seize to the CV axle spline.
10. 10

    Install knuckle onto CV axle
    Guide the new or rebuilt knuckle assembly onto the CV axle shaft, ensuring the splines engage properly. Push the knuckle fully onto the axle shaft and position it for connection to the ball joint and strut.
11. 11

    Connect lower ball joint
    Raise the lower control arm with the floor jack to align the ball joint stud with the hole in the bottom of the knuckle. Insert the stud into the knuckle and install the new castle nut. Torque to specification and install a new cotter pin, advancing the nut only enough to align the cotter pin hole.
    ⚠Never back off a castle nut to align the cotter pin hole. Only advance the nut if needed for alignment.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
12. 12

    Connect strut to knuckle
    Align the knuckle with the strut and insert the two pinch bolts through the strut and knuckle. Install the nuts and torque to specification in an alternating pattern.
    Torque spec

    Strut Bolts133 Nm (98 lb-ft)
13. 13

    Reconnect remaining components
    Reconnect the outer tie rod end to the knuckle and install the castle nut with new cotter pin. Reconnect the sway bar link to the lower control arm, holding the shaft with an Allen key while torquing the nut. Install the brake dust shield. Install the ABS sensor into the knuckle and reconnect the electrical connector.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
14. 14

    Install brake components
    Install the brake rotor onto the hub. Remove the caliper from its hanger and position it over the rotor. Install and torque the caliper mounting bolts. Pump the brake pedal several times to restore brake pressure before moving the vehicle.
15. 15

    Install wheel and axle nut
    Install a new axle hub nut and hand-tighten. Install the wheel and hand-tighten the lug nuts. Lower the vehicle to the ground. With the vehicle on the ground, torque the lug nuts in a star pattern to specification. Apply the parking brake and torque the axle hub nut to the proper specification (typically 250+ lb-ft, verify with service manual).
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to proper specifications using a calibrated torque wrench
2. Verify brake pedal is firm before attempting to move vehicle
3. Check that ABS sensor is properly seated and connector is secure
4. Verify CV axle nut is properly torqued to prevent wheel bearing damage

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises from the front suspension
• Check for proper steering response with no binding or unusual resistance
• Verify ABS warning light does not illuminate on the dashboard
• Schedule a professional front-end alignment as soon as possible after this repair
• Inspect for any fluid leaks around the brake caliper and CV axle seal after test drive
• Recheck all critical torque specifications after 50-100 miles of driving

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