This procedure covers the replacement of both upper and lower ball joints on the front suspension of a 2015-2020 Ford F-150 with 5.0L V8 Coyote engine, requiring removal of the steering knuckle assembly.

Warnings

Tools required

Parts

• Upper ball joint × 2 — Motorcraft or equivalent for F-150 front upper
• Lower ball joint × 2 — Motorcraft or equivalent for F-150 front lower
• Cotter pins for ball joint nuts × 4 — Use OEM specification
• Pinch bolts × 2 — Use OEM specification
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground but do not remove
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove front wheels completely
5. Spray all ball joint nuts, pinch bolts, and control arm connections with penetrating oil
6. Allow penetrating oil to soak for 15-20 minutes before beginning work

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar end link connection at the lower control arm. Hold the center shaft with an Allen key to prevent rotation while removing the nut with a socket. Disconnect the sway bar link from the lower control arm.
   Torque spec

   Sway Bar Link76 Nm (56 lb-ft)
2. 2

   Remove brake caliper and rotor
   Remove the two brake caliper bracket bolts and carefully remove the caliper and bracket assembly. Support the caliper with wire or a bungee cord to avoid stressing the brake hose. Do not let it hang by the hose. Slide the brake rotor off the hub.
   ⚠Never let brake caliper hang by the brake hose as this can damage internal hose structure.
3. 3

   Remove ABS sensor wire and hub assembly
   Disconnect the ABS wheel speed sensor electrical connector. Remove any clips securing the sensor wire to the knuckle. Remove the hub bearing bolts from the back of the steering knuckle (accessed from behind). Carefully pull the hub assembly out of the knuckle. If stuck, use a slide hammer or carefully tap from behind.
   ⚠Do not damage ABS sensor or wiring during removal. Handle hub assembly carefully to avoid damaging bearing seals.
4. 4

   Disconnect tie rod end
   Remove the cotter pin from the tie rod end castle nut. Loosen but do not fully remove the castle nut. Use a ball joint separator or pickle fork to separate the tie rod end from the steering knuckle. Once separated, remove the nut completely and swing the tie rod out of the way.
   ⚠Do not strike the tie rod end threads directly with a hammer. Leave nut partially threaded to protect threads during separation.
5. 5

   Separate upper ball joint from knuckle
   Remove the cotter pin from the upper ball joint castle nut using side cutters or a cotter pin puller. Loosen the upper ball joint nut but leave it threaded on a few turns. Use a ball joint separator to break the taper between the ball joint stud and knuckle. Once separated, remove the nut completely.
   ⚠Keep nut partially threaded during separation to prevent sudden dropping of knuckle when taper breaks free.
   Torque spec

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

   Separate lower ball joint and remove knuckle
   Remove the cotter pin from the lower ball joint castle nut. Remove the castle nut completely. Use a ball joint separator to break the taper between the lower ball joint stud and the knuckle. Support the knuckle as you separate it. Once both ball joints are disconnected, remove the steering knuckle assembly from the vehicle.
   ⚠Knuckle assembly is heavy. Support it during removal to prevent it from falling.
   Torque spec

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

   Press out old ball joints
   Secure the steering knuckle in a vise or on a stable work surface. Using a ball joint press or C-frame press with appropriate adapters, press out the upper ball joint first. Position the press to push the ball joint out without damaging the knuckle bore. Repeat the process for the lower ball joint. Clean the ball joint bores thoroughly with a wire brush and inspect for damage.
   ⚠️Ball joint pressing requires extreme force. Ensure press is properly aligned and secure before applying pressure. Wear safety glasses as metal can deform or fracture.
   ⚠Do not damage the ball joint bore surfaces in the knuckle during removal. Any scoring or deformation may require knuckle replacement.
8. 8

   Install new ball joints
   Apply a light coat of anti-seize to the outer diameter of the new ball joint housings (not the tapered stud). Position the new lower ball joint in the knuckle bore and use the ball joint press to press it fully into place until seated. The ball joint should be flush and fully seated in the bore. Repeat for the upper ball joint. Ensure both ball joints are pressed in straight and seated completely.
   ⚠Press ball joints in straight to avoid cocking them in the bore. Misalignment can cause premature failure.
9. 9

   Reinstall steering knuckle
   Position the steering knuckle assembly back into place on the vehicle. Insert the lower ball joint stud into the lower control arm and thread on the castle nut hand-tight. Insert the upper ball joint stud into the upper control arm and thread on the castle nut hand-tight. Support the knuckle to maintain alignment.
   ℹ️You may need to use a pry bar or jack to align the ball joint studs with the control arm mounting holes.
10. 10

    Torque ball joint castle nuts
    Using a torque wrench, torque the upper ball joint castle nut to specification. Align the castle nut slots with the hole in the stud and install a new cotter pin. Bend the cotter pin ends to secure. Torque the lower ball joint castle nut to specification, align the castle nut slots, and install a new cotter pin. Bend the cotter pin ends to secure.
    ℹ️If castle nut slots do not align with cotter pin hole, tighten the nut further until alignment is achieved. Never loosen the nut to align.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
11. 11

    Reconnect tie rod end
    Insert the tie rod end stud into the steering knuckle. Thread on the castle nut and torque to specification (refer to tie rod end specification if available in your service manual). Install a new cotter pin through the castle nut and stud, then bend the ends to secure.
    ℹ️Ensure tie rod end is properly seated in the knuckle taper before torquing.
12. 12

    Reinstall hub assembly
    Clean the hub mounting surface on the back of the steering knuckle. Install the hub bearing assembly into the knuckle, ensuring the ABS sensor tone ring (if integral to hub) is properly oriented. Install and torque the hub mounting bolts from the rear of the knuckle according to manufacturer specifications. Reconnect the ABS sensor connector and secure the wire with clips.
    ℹ️Ensure hub is fully seated in knuckle before tightening bolts. Hub should sit flush against knuckle face.
13. 13

    Reinstall brake components
    Slide the brake rotor onto the hub. Position the brake caliper and bracket assembly over the rotor and align with the mounting holes. Install the caliper bracket bolts and torque to specification per your service manual. Pump the brake pedal several times to restore caliper piston position.
    ⚠Verify brake caliper bolts are torqued properly. Improperly torqued caliper brackets can cause brake failure.
14. 14

    Reconnect sway bar link
    Connect the sway bar end link to the lower control arm. Install the nut and hold the center shaft with an Allen key while torquing the nut to specification.
    Torque spec

    Sway Bar Link76 Nm (56 lb-ft)
15. 15

    Reinstall wheels and perform final torque
    Install the wheels and thread lug nuts on by hand. Lower the vehicle until the tires just touch the ground but suspension is not fully loaded. Torque wheel lug nuts to specification in a star pattern. Fully lower the vehicle to the ground. If control arm bushings were disturbed during the procedure, torque control arm bolts to specification with vehicle weight on wheels.
    ℹ️Control arm bolts must be torqued at ride height with vehicle weight on suspension to prevent bushing bind and premature wear.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both sides
2. Verify all fasteners are properly torqued including ball joint castle nuts, wheel lug nuts, and control arm bolts
3. Ensure all cotter pins are properly installed and bent to prevent backing out
4. Check that brake caliper is secure and brake pedal is firm before moving vehicle

Verification

• Test drive vehicle in a safe area at low speed and verify no unusual noises from front suspension
• Check for proper steering response and straight-line tracking
• Perform a visual inspection underneath to confirm no loose components or leaking fluids
• Schedule a professional wheel alignment as suspension geometry has been altered
• After 50-100 miles, re-torque wheel lug nuts and verify all suspension fasteners remain tight

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