This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2011-2014 Ford F-150 4WD with 5.0L Coyote V8 engine, including disconnection of all suspension and steering components.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM specification
• Wheel hub and bearing assembly × 1 — Use OEM specification
• Front axle shaft nut × 1 — One-time use fastener
• Upper ball joint nut × 1 — Replace if damaged
• Lower ball joint nut × 1 — Replace if damaged
• Tie rod end nut × 1 — Replace if damaged
• ABS sensor (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Loosen front axle shaft nut while vehicle is on ground with brakes applied, but do not remove completely
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise and support vehicle on jack stands at frame rails
5. Remove wheel and tire assembly
6. Apply penetrating oil to all suspension fasteners and allow to soak for best results
7. Support lower control arm with floor jack to relieve suspension load

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts from the rear of the caliper. Lift caliper off rotor and secure to frame or upper control arm using wire or a caliper hanger - do not allow it to hang by the brake hose. Remove brake rotor by pulling straight off the hub. If rotor is stuck, use penetrating oil and light tapping with a rubber mallet.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
2. 2

   Disconnect ABS sensor
   Locate the ABS wheel speed sensor wire connector near the strut assembly. Disconnect the electrical connector. Remove the ABS sensor mounting bolt and carefully extract the sensor from the knuckle. Set aside in a clean area. If sensor is damaged or seized in the knuckle, it must be replaced.
3. 3

   Remove axle shaft nut and disconnect CV axle
   Fully remove the front axle shaft nut that was previously loosened. Use a pry bar or suitable tool to push the CV axle shaft back through the hub assembly. You may need to tap the end of the shaft with a soft mallet. The shaft does not need to be fully removed from the differential at this time, just separated from the hub.
   ℹ️The axle shaft may be tight in the hub. Do not damage CV boot or threads while separating.
4. 4

   Disconnect tie rod end
   Remove the cotter pin and castle nut from the tie rod end ball stud. Use a tie rod end separator or pickle fork to separate the tie rod end from the knuckle. Strike the separator tool firmly to break the taper. Once separated, move the tie rod out of the way.
   ⚠Using a pickle fork will damage the tie rod end boot. Replace tie rod end if boot is torn.
5. 5

   Disconnect sway bar link
   Locate the sway bar end link attached to the lower control arm. Hold the shaft with an Allen key to prevent rotation. Remove the lower sway bar link nut and separate the link from the lower control arm.
   Torque spec

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

   Disconnect upper ball joint
   Remove the upper ball joint castle nut and cotter pin. Use a ball joint separator to break the taper between the ball joint stud and the knuckle. Position the separator tool carefully and strike firmly. Once separated, the upper control arm can pivot upward away from the knuckle.
   ⚠Support the knuckle assembly before separating the upper ball joint to prevent it from falling.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
7. 7

   Remove strut-to-knuckle bolts
   Locate the two bolts securing the strut to the steering knuckle. These are large pinch bolts that clamp the knuckle to the strut. Remove both bolts completely. You may need to support the knuckle with one hand or a jack as you remove the second bolt.
   ℹ️Mark the position of the strut cam bolts if equipped to assist with alignment during reassembly.
   Torque spec

   Strut Bolts144 Nm (106 lb-ft)
8. 8

   Disconnect lower ball joint
   Remove the lower ball joint castle nut and cotter pin. Use a ball joint separator to break the taper between the lower ball joint stud and the knuckle. The knuckle assembly is now free from all suspension and steering connections.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
9. 9

   Remove knuckle and hub assembly
   Carefully maneuver the steering knuckle assembly away from the vehicle, threading it past the CV axle shaft. The hub and bearing assembly is typically pressed into the knuckle and may come out as one unit. Place the assembly on a clean workbench for hub removal if needed.
10. 10

    Remove hub from knuckle (if reusing knuckle)
    If you are only replacing the knuckle and reusing the hub, or vice versa, the hub must be pressed out. Use a hub puller or press to remove the wheel bearing and hub assembly from the knuckle. Note the direction of installation. If replacing the entire assembly, skip this step and install the new hub already pressed into the new knuckle.
    ℹ️Many replacement knuckles come with the hub and bearing pre-installed. Verify what is included with your replacement part.
11. 11

    Prepare and install new knuckle assembly
    Clean all mating surfaces on the ball joints, strut, and tie rod end with a wire brush. Inspect all tapered mounting surfaces for damage. If the new knuckle does not include a hub, press the hub and bearing assembly into the new knuckle using a hydraulic press. Position the new knuckle assembly into place, threading it over the CV axle shaft.
12. 12

    Reconnect lower ball joint
    Align the lower ball joint stud with the hole in the knuckle. Install the castle nut and torque to specification. Install a new cotter pin and bend the ends to secure. Ensure the ball joint stud is fully seated in the taper.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
13. 13

    Reconnect strut to knuckle
    Align the knuckle with the strut assembly. If cam bolts were present, align marks made during disassembly. Insert both strut-to-knuckle bolts and torque to specification. Ensure the pinch joint is fully seated before tightening.
    Torque spec

    Strut Bolts144 Nm (106 lb-ft)
14. 14

    Reconnect upper ball joint
    Pull the upper control arm down and align the upper ball joint stud with the hole in the top of the knuckle. Install the castle nut and torque to specification. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
15. 15

    Reconnect CV axle and install new axle nut
    Push the CV axle shaft through the hub and bearing assembly until it is fully seated. Clean the threads on the axle shaft. Install a new axle shaft nut and tighten by hand. Final torque will be applied with the vehicle on the ground.
    ℹ️Always use a new axle shaft nut. These are torque-to-yield fasteners and cannot be reused.
16. 16

    Reconnect tie rod end
    Insert the tie rod end ball stud into the knuckle. Install the castle nut and torque to specification per manufacturer (typically 60-85 ft-lb for this vehicle). Install a new cotter pin and bend ends to secure. Do not loosen the nut to align cotter pin holes - only tighten up to the next slot.
17. 17

    Reconnect sway bar link
    Connect the sway bar end link to the lower control arm. Hold the shaft with an Allen key and install the nut. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
18. 18

    Install ABS sensor
    Clean the ABS sensor bore in the knuckle. Apply a thin coat of anti-seize to the sensor body (not the tip). Insert the ABS sensor into the knuckle and install the mounting bolt. Torque to specification. Reconnect the electrical connector and secure the wire routing to prevent damage.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
19. 19

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub. Verify it seats flat against the hub face. Position the brake caliper over the rotor and align with the mounting bracket. Install both caliper mounting bolts and torque to specification.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
20. 20

    Install wheel and final torque procedures
    Install the wheel and tire assembly. Install lug nuts and torque to specification in a star pattern. Lower the vehicle to the ground. With the vehicle on the ground and brakes applied, torque the front axle shaft nut to manufacturer specification (typically 184 ft-lb for this application). Pump the brake pedal several times to restore brake pressure before moving the vehicle.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification, especially the critical ball joint, strut, and axle shaft fasteners
2. Verify the CV axle shaft nut is torqued with vehicle weight on the ground
3. Double-check that all cotter pins are properly installed and bent
4. Confirm brake caliper bolts are tight and caliper operates freely
5. Verify ABS sensor connector is fully seated and wire is properly routed away from moving components

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises from the suspension or steering
• Check for proper brake operation and no pulsation or pulling
• Verify the ABS warning light is not illuminated on the instrument cluster
• Inspect all connections for proper seating and torque
• Schedule a professional 4-wheel alignment as soon as possible - suspension geometry has been altered and the vehicle will not handle properly without alignment
• After 50-100 miles, re-torque all critical fasteners including lug nuts, ball joint nuts, and strut bolts

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