This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2011-2014 Ford F-150 4WD with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
• Ball joint nut × 1 — Replace if damaged
• ABS sensor (if equipped) × 1 — Transfer from old knuckle or replace

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise and safely support the rear of the vehicle on jack stands at the frame rails
4. Remove the rear wheel on the side being serviced
5. Spray all suspension fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully remove the caliper. Support the caliper with wire or a hanger to avoid stressing the brake hose. Do not let it hang by the brake line. Remove the brake rotor by pulling it off the hub. If stuck, use penetrating oil and light hammer taps.
2. 2

   Disconnect ABS sensor
   If equipped with ABS, locate the wheel speed sensor on the knuckle. Disconnect the electrical connector and remove the sensor mounting bolt. Carefully remove the sensor from the knuckle to avoid damage. Note the routing of the sensor wire for reinstallation.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Remove sway bar link
   Locate the rear sway bar link connection at the knuckle or lower control arm. Hold the shaft with an Allen key to prevent rotation and remove the upper or lower nut as needed. Separate the sway bar link from the knuckle assembly.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Remove shock/strut lower mounting bolts
   Support the lower control arm with a floor jack positioned under the arm near the knuckle to control the suspension as fasteners are removed. Remove the lower shock/strut mounting bolts that attach to the knuckle or lower control arm. Keep track of any washers or spacers.
   ⚠The floor jack must support the lower control arm to prevent sudden suspension drop when bolts are removed.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
5. 5

   Separate upper ball joint
   Remove the upper ball joint castle nut from the knuckle. Use a ball joint separator or pickle fork to separate the upper ball joint stud from the knuckle. Take care not to damage the ball joint boot if reusing components. The knuckle will begin to drop as the ball joint separates.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
6. 6

   Remove knuckle from lower control arm
   With the upper ball joint separated, carefully lower the floor jack to relieve tension. Remove the bolts securing the knuckle to the rear lower control arm. The exact attachment method varies by suspension configuration, but typically involves two horizontal bolts through the knuckle. Remove these bolts and separate the knuckle from the lower control arm.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove knuckle assembly
   With all connections separated, carefully remove the knuckle/spindle assembly from the vehicle. Inspect the mating surfaces on the control arms and upper ball joint for damage, corrosion, or excessive wear. Clean all mounting surfaces with a wire brush.
8. 8

   Install new knuckle to lower control arm
   Position the new knuckle assembly onto the lower control arm. Install the control arm bolts finger-tight only at this stage. Ensure the knuckle is properly seated and aligned with the control arm mounting points. Do not torque these bolts yet as they must be torqued with vehicle weight on wheels.
9. 9

   Connect upper ball joint
   Raise the knuckle assembly using the floor jack under the lower control arm until the upper ball joint stud aligns with the hole in the knuckle. Insert the ball joint stud into the knuckle and install the castle nut. Torque the castle nut to specification and install a new cotter pin if equipped. If the castle nut slots don't align, tighten slightly more (never loosen) to align.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
10. 10

    Install shock/strut mounting bolts
    Align the shock/strut lower mounting bracket with the knuckle or control arm. Install the mounting bolts with any washers or spacers in their original positions. Torque the strut bolts to specification.
    Torque spec

    Strut Bolts133 Nm (98 lb-ft)
11. 11

    Reconnect sway bar link
    Connect the sway bar link to the knuckle or lower control arm. 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)
12. 12

    Install ABS sensor and brake components
    If equipped, install the ABS wheel speed sensor into the knuckle and torque the mounting bolt to specification. Reconnect the electrical connector and secure the wiring in its original routing. Install the brake rotor onto the hub. Position the brake caliper over the rotor and install the caliper mounting bolts to manufacturer specification.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Install wheel and lower vehicle
    Install the rear wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but the suspension is not yet fully loaded. This is when control arm bolts should be torqued.
14. 14

    Torque control arm bolts with vehicle weight
    With the vehicle weight resting on the wheels but still partially supported by the jack, torque the control arm bolts to specification. This ensures the bushings are torqued in their normal operating position, preventing premature wear. Fully lower the vehicle and remove jack stands.
    ℹ️Control arm bolts must be torqued with vehicle weight on suspension to prevent bushing damage.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
15. 15

    Final torque wheel lug nuts
    With the vehicle on the ground, torque the wheel lug nuts to specification in a star pattern. Perform a final check of all fasteners installed during this procedure.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. All fasteners should be inspected and replaced if damaged or corroded
2. Control arm bolts MUST be torqued with vehicle weight on wheels to prevent bushing failure
3. If castle nuts are used on ball joints, always use new cotter pins

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the rear suspension
• Check for proper brake operation and pedal feel
• Have a professional wheel alignment performed immediately, as the rear suspension geometry has been altered
• Re-torque wheel lug nuts after 50-100 miles of driving

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