This procedure covers the replacement of both upper and lower ball joints on the front suspension of a 2011-2014 Ford F-150 4WD with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• Upper ball joint (per side) × 2 — Use OEM specification or Moog K80930
• Lower ball joint (per side) × 2 — Use OEM specification or Moog K80929
• Cotter pins × 4 — Use OEM specification
• Pinch bolts × 2 — Use OEM specification

Preparation

1. Park vehicle on level 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 under frame rails
4. Remove both front wheels completely
5. Spray all ball joint nuts, pinch bolts, and sway bar link nuts with penetrating oil and allow to soak for 15-20 minutes

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connecting the sway bar to the lower control arm. Hold the ball stud shaft with an Allen key while loosening the nut with a wrench. Remove the nut and disconnect the sway bar link from the lower control arm. Allow the sway bar to hang free.
2. 2

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with wire or a bungee cord to avoid stressing the brake hose. Do not let it hang by the brake line. Remove the rotor by pulling it straight off the hub. If seized, use light hammer taps on the back side to break it free.
3. 3

   Remove wheel speed sensor
   Locate the ABS wheel speed sensor mounted on the knuckle. Disconnect the electrical connector and remove the mounting bolt. Carefully pull the sensor straight out of the knuckle bore. Set aside to prevent damage during ball joint separation.
   ⚠ABS sensors are fragile. Do not pry or bend the sensor tip as this will cause failure and require replacement.
4. 4

   Remove knuckle pinch bolt
   Locate the pinch bolt that secures the lower ball joint stud to the steering knuckle. This is a horizontal bolt that passes through a clamping slot in the knuckle. Remove this bolt completely and discard it. A new pinch bolt must be installed during reassembly.
5. 5

   Separate upper ball joint from knuckle
   Remove the cotter pin from the upper ball joint castle nut and discard. Using a 21mm socket, loosen and remove the upper ball joint nut. Use a ball joint separator tool or pickle fork to separate the ball joint stud from the knuckle. Strike the separator tool firmly with a hammer until the taper breaks free. Be careful not to damage the CV boot or brake components.
   ⚠The upper ball joint may release suddenly when the taper breaks. Keep hands and face clear of the separation point.
6. 6

   Remove knuckle assembly
   With both the upper ball joint nut removed and the lower pinch bolt removed, spread the pinch slot on the knuckle slightly with a pry bar if necessary. Pull the knuckle assembly outward and downward to separate it from both ball joint studs. Remove the knuckle completely from the vehicle and set aside on a clean work surface.
7. 7

   Press out old upper ball joint
   Secure the upper control arm in a vise or stable position. Select the appropriate receiver cup and press adapter for the upper ball joint from your ball joint press kit. Position the receiver cup under the control arm to support it around the ball joint. Install the press screw and adapter from above, centered on the ball joint. Tighten the press slowly and evenly until the old upper ball joint is pressed completely out of the control arm. Clean the bore thoroughly with a wire brush.
   ⚠️Ensure ball joint press components are properly aligned before applying force. Misalignment can cause components to slip and cause injury.
8. 8

   Press in new upper ball joint
   Position the new upper ball joint in the control arm bore, ensuring it is oriented correctly with the stud pointing downward. Select the appropriate press adapter that contacts only the ball joint body, not the stud or boot. Install the ball joint press with the receiver cup supporting the control arm from below. Press the new ball joint in slowly and evenly until it is fully seated and flush with the control arm. Verify the ball joint is seated completely around its entire circumference.
9. 9

   Press out old lower ball joint
   Position the lower control arm securely with the ball joint accessible. The lower ball joint is larger and requires more force to remove. Select the appropriate receiver cup and press adapter for the lower ball joint. Position the press and apply steady pressure to drive the old lower ball joint out of the control arm. Clean the bore thoroughly with a wire brush and inspect for damage or deformation.
10. 10

    Press in new lower ball joint
    Position the new lower ball joint in the control arm bore with correct orientation. Use the appropriate press adapter that supports the ball joint body evenly. Press the new ball joint in slowly until fully seated and flush with the control arm surface. The lower ball joint requires significant force to seat properly. Verify complete seating around the entire circumference.
11. 11

    Install knuckle onto ball joints
    Lift the knuckle assembly into position and align the lower ball joint stud with the pinch slot in the knuckle. Insert the lower ball joint stud into the knuckle and spread the pinch slot slightly if needed to allow insertion. Align the upper ball joint stud with the upper hole in the knuckle and insert it through. Install the upper ball joint castle nut hand-tight.
12. 12

    Install new pinch bolt and torque upper ball joint
    Install a new pinch bolt through the lower ball joint pinch slot. Ensure the pinch slot clamps properly around the ball joint stud. Torque the pinch bolt to specification. Next, torque the upper ball joint castle nut to the specified value. If the castle nut slots do not align with the cotter pin hole, tighten further (do not loosen) until alignment is achieved. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Pinch Bolt76 Nm (56 lb-ft)

    Ball Joint Nut127 Nm (94 lb-ft)
13. 13

    Reinstall wheel speed sensor and brake components
    Clean the wheel speed sensor bore in the knuckle. Apply a thin coat of high-temperature anti-seize to the sensor body (not the tip). Install the sensor into the knuckle bore and secure with the mounting bolt. Reconnect the electrical connector. Reinstall the brake rotor onto the hub, then position the brake caliper over the rotor and install the caliper mounting bolts to specification.
14. 14

    Reconnect sway bar link
    Position the sway bar link ball stud through the mounting hole in the lower control arm. Install the nut and hold the ball stud shaft with an Allen key while tightening the nut to specification.
    Torque spec

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

    Install wheels and perform final torque
    Install the wheel onto the hub and thread on the lug nuts. Tighten the lug nuts in a star pattern snug but not to final torque. Lower the vehicle until the tires just contact the ground but suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both sides
2. After both sides are complete, start the engine and turn the steering wheel lock-to-lock several times while stationary to verify no interference or binding
3. Test drive the vehicle at low speed in a safe area to verify proper operation before returning to normal service

Verification

• Verify all torque specifications have been met, especially ball joint nuts and pinch bolts
• Check that all cotter pins are properly installed and bent to prevent backing out
• Confirm no play exists in ball joints by lifting vehicle slightly and attempting to move wheel vertically and horizontally
• Inspect for any fluid leaks around brake components
• Test steering for smooth operation with no binding or unusual noises
• Schedule a professional alignment immediately after completing this repair, as ball joint replacement affects suspension geometry

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