This procedure covers the removal and replacement of the lower ball joint on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine. The ball joint connects the lower control arm to the steering knuckle.

Warnings

Tools required

Parts

• Lower ball joint assembly × 1 — Use OEM specification or equivalent Motorcraft part
• Cotter pin × 1 — New cotter pin for ball joint nut
• Pinch bolt × 1 — New pinch bolt as specified

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands placed on frame rails
4. Remove wheel and tire assembly
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the control arm and prevent it from dropping when the ball joint is separated. Raise jack just enough to contact the arm without lifting the vehicle.
2. 2

   Remove ball joint cotter pin
   Locate the ball joint castle nut on the steering knuckle. Straighten and remove the cotter pin using needle nose pliers. Discard the old cotter pin.
3. 3

   Loosen ball joint nut
   Using a breaker bar and appropriate socket, loosen the ball joint castle nut but do not remove it completely. Leave the nut threaded on 2-3 turns to protect the threads and prevent the joint from separating violently.
   ⚠Leaving the nut partially threaded prevents the ball joint from suddenly separating and causing injury or component damage.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the ball joint stud from the steering knuckle. Position the tool between the knuckle and control arm, then strike sharply with a hammer or apply pressure per tool design. Once separated, remove the castle nut completely.
   ⚠The lower control arm will drop slightly when the ball joint separates. Ensure the floor jack is supporting the control arm.
5. 5

   Remove lower control arm (if necessary)
   If the ball joint is pressed into the control arm, you may need to remove the entire control arm for easier access to press out the old ball joint. Remove the control arm mounting bolts from the frame. Note the position and orientation of any shims or alignment cams for reassembly.
6. 6

   Remove old ball joint
   Using a ball joint press kit with appropriate adapters, press the old ball joint out of the control arm. Position the receiving cup to support the control arm around the ball joint bore, and press from the bottom of the control arm. Clean the ball joint bore thoroughly with a wire brush, removing any rust or debris.
   ℹ️Ensure the press is properly aligned to prevent damage to the control arm bore. The ball joint should press out with steady pressure.
7. 7

   Install new ball joint
   Position the new ball joint in the control arm bore with the grease fitting and stud oriented correctly. Using the ball joint press with appropriate adapters, press the new ball joint into the control arm until it is fully seated. The ball joint should be flush with the control arm surface or seated to the depth specified by the manufacturer.
   ⚠Do not press on the ball joint stud. Apply force only to the outer housing of the ball joint.
8. 8

   Reinstall lower control arm
   If removed, position the lower control arm back into place on the frame mounts. Install the control arm bolts hand-tight only at this stage. Ensure any alignment shims or cams are reinstalled in their original positions. Do not torque the control arm bolts yet.
   ℹ️Control arm bolts must be torqued with the vehicle weight on the wheels to prevent binding in the bushings.
9. 9

   Connect ball joint to knuckle
   Raise the lower control arm using the floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and thread on the new castle nut. Tighten the nut to specification.
   Torque spec

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

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud. If the cotter pin holes do not align, tighten the nut further (do not loosen) until the next slot aligns with the hole. Bend the cotter pin ends to secure.
    ℹ️Never loosen the castle nut to align the cotter pin. Always tighten to the next alignment point.
11. 11

    Install wheel and lower vehicle
    Reinstall the wheel and tire assembly. Thread all lug nuts by hand, then snug them in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Remove the jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
12. 12

    Torque control arm bolts
    With the vehicle weight now on the wheels (suspension at normal ride height), torque the lower control arm mounting bolts to specification. This ensures the bushings are not preloaded in a twisted position.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Final torque wheel lug nuts
    Lower the vehicle completely to the ground. Perform final torque of the wheel lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify the cotter pin is properly installed and secured
3. Check that the ball joint grease fitting is accessible for future maintenance

Verification

• Start the vehicle and turn the steering wheel fully left and right while stationary to verify no binding or unusual noises
• Test drive the vehicle at low speed and verify normal steering response and no clunking noises over bumps
• Perform a visual inspection underneath to confirm all fasteners are tight and the cotter pin is secure
• Have the front end alignment checked and adjusted by a professional alignment shop, as ball joint replacement affects alignment settings

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