This procedure covers the removal and replacement of the rear wheel knuckle/spindle assembly on a 2011-2014 Ford F-150 4WD with 5.0L V8 engine.

Warnings

Tools required

Parts

• Rear wheel knuckle/spindle assembly × 1 — Use OEM specification
• Wheel bearing and hub assembly (if not included with knuckle) × 1 — Use OEM specification
• Ball joint nut (castle nut) × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle and support securely on jack stands at frame rails
5. Remove rear wheel completely
6. Spray all fasteners with penetrating oil and allow to soak for 15-20 minutes

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts from the back of the caliper adapter. Carefully remove the caliper and hang it from the frame using a wire or caliper hanger to avoid tension on the brake hose. Do not let the caliper hang by the brake line. Remove the brake rotor by pulling it straight off the hub.
2. 2

   Disconnect ABS sensor
   Locate the ABS wheel speed sensor connector near the knuckle. Press the release tab and disconnect the sensor connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Note the routing of the sensor wire for reinstallation.
3. 3

   Disconnect sway bar link
   Locate the rear sway bar end link where it connects to the knuckle or lower control arm. Use an Allen key to hold the shaft of the link while removing the upper or lower nut (whichever provides access to the knuckle). Separate the link from the mounting point.
   Torque spec

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

   Remove shock/strut lower mounting bolt
   Locate the lower shock absorber or strut mounting bolt that connects to the knuckle or lower control arm. Support the lower control arm with a floor jack to prevent sudden drop. Remove the bolt completely and retain for inspection.
   Torque spec

   Strut Bolts144 Nm (106 lb-ft)
5. 5

   Separate upper ball joint
   Remove the cotter pin from the upper ball joint castle nut. Loosen but do not fully remove the ball joint nut. Use a ball joint separator or pickle fork to break the taper between the ball joint stud and knuckle. Once separated, remove the nut completely. Support the knuckle to prevent it from falling.
   ⚠Keep the ball joint nut threaded on a few turns while using the separator to prevent sudden separation and component damage.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
6. 6

   Disconnect lower control arm from knuckle
   Locate the lower control arm to knuckle connection point. If equipped with a ball joint at the lower position, repeat the separation process from step 5. If equipped with a bolt-through connection, remove the control arm mounting bolts. The knuckle should now be free to pivot.
   Torque spec

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

   Remove wheel hub and bearing assembly
   If the hub and bearing are integral to the knuckle being replaced, remove the hub mounting bolts from the back of the knuckle (typically 4 bolts). If the hub is seized, use a hub puller to extract it. Clean the mounting surface thoroughly with a wire brush.
8. 8

   Remove knuckle from vehicle
   With all connections disconnected, carefully maneuver the knuckle assembly away from the vehicle. Note the orientation and position of any shims or spacers. Inspect all mounting points on the vehicle for damage or excessive wear.
9. 9

   Prepare new knuckle assembly
   Compare the new knuckle to the old unit to verify correct application. If the wheel bearing and hub are separate, press or bolt the new bearing into the knuckle according to manufacturer specifications. Apply a thin coat of anti-seize to the hub mounting surface and ball joint tapers.
10. 10

    Install new knuckle
    Position the new knuckle into place, aligning it with the upper ball joint or mounting point first. Insert the upper ball joint stud into the knuckle taper. Thread the new ball joint nut on hand-tight. Support the knuckle while connecting the lower control arm.
11. 11

    Connect lower control arm
    Align the lower control arm to the knuckle mounting point. Install the lower ball joint or control arm bolts hand-tight. Do not fully torque control arm bolts at this time as they must be torqued at ride height with vehicle weight on the wheels.
12. 12

    Torque ball joint and reinstall shock
    Torque the upper ball joint nut to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure. Align the shock/strut lower mount to the knuckle or control arm and install the bolt. Torque to specification.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)

    Strut Bolts144 Nm (106 lb-ft)
13. 13

    Reconnect sway bar and ABS sensor
    Connect the sway bar end link to its mounting point on the knuckle or control arm. Hold the shaft with an Allen key and torque the nut to specification. Install the ABS wheel speed sensor into the knuckle, ensuring the O-ring is properly seated. Route the wire as documented in preparation photos and reconnect the connector.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
14. 14

    Reinstall brake components
    Clean the hub face with a wire brush. Install the brake rotor, ensuring it seats flush against the hub. Position the brake caliper over the rotor and install the caliper mounting bolts to the adapter. Clean brake caliper bolt threads and apply threadlocker if specified by manufacturer.
15. 15

    Install wheel and perform final torque
    Install the wheel and thread lug nuts hand-tight. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the lug nuts in a star pattern to specification. Lower the vehicle completely to the ground with full weight on the wheels. Now torque the control arm bolts to specification while at ride height.
    ⚠Control arm bolts MUST be torqued with vehicle weight on the wheels to prevent premature bushing failure.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. After completing the procedure, pump the brake pedal several times to restore brake pressure before moving the vehicle
2. Double-check that all fasteners have been installed and properly torqued
3. Verify the ABS sensor connector is fully seated and the wire is properly routed away from moving components

Verification

• Test drive the vehicle in a safe area at low speed, checking for abnormal noises, vibrations, or pulling
• Verify proper brake operation and pedal feel
• Check that the ABS warning light is not illuminated on the instrument cluster
• After 50-100 miles of driving, re-torque all critical fasteners including lug nuts and control arm bolts
• Schedule a professional wheel alignment as soon as possible, as rear suspension geometry has been altered

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