This procedure covers the removal and replacement of the rear knuckle/spindle assembly on a 2015-2020 Ford F-150 with RWD configuration, including disconnection of suspension components and brake hardware.

Warnings

Tools required

Parts

• Rear knuckle/spindle assembly × 1 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification
• Wheel bearing and hub assembly (if integrated) × 1 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

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

Procedure

1. 1

   Remove brake caliper
   Remove the two brake caliper mounting bolts from the back of the knuckle. Support the caliper with wire or zip ties to the suspension or frame. Do not let the caliper hang by the brake hose as this can damage the hose internally.
   Torque spec

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

   Remove brake rotor
   Remove the brake rotor from the hub. If rotor is stuck, thread two M8 bolts into the threaded holes on the rotor face to press it off the hub. Clean the hub surface with a wire brush.
3. 3

   Disconnect ABS sensor
   Locate the ABS wheel speed sensor connector near the knuckle. Disconnect the electrical connector and remove any retaining clips securing the sensor wire to the knuckle. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle to prevent damage.
4. 4

   Disconnect sway bar link
   Locate the sway bar link connection at the lower control arm or knuckle. Hold the shaft with an Allen key to prevent spinning, then remove the upper and lower sway bar link nuts. Remove the sway bar link from the knuckle area.
   Torque spec

   Sway Bar Link76 Nm (56 lb-ft)
5. 5

   Remove shock absorber lower mounting
   Support the lower control arm with a floor jack to maintain suspension position. Remove the lower shock absorber mounting bolt that connects the shock to the lower control arm or knuckle bracket. Carefully lower the jack slightly to relieve tension.
   ⚠The lower control arm will drop when the shock is disconnected. Use a jack to control the descent and prevent sudden movement.
   Torque spec

   Strut Bolts144 Nm (106 lb-ft)
6. 6

   Disconnect upper ball joint
   Remove the castle nut from the upper ball joint stud and remove the cotter pin. Use a ball joint separator tool to separate the upper ball joint from the knuckle. Strike the knuckle boss with a hammer while applying pressure with the separator if needed.
   Torque spec

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

   Mark control arm cam bolts position
   Before removing lower control arm bolts, mark the position of any cam bolts or eccentric washers with paint or a scribe. This preserves the alignment settings and makes reassembly easier. Take photos for reference.
8. 8

   Disconnect lower control arm
   With the lower control arm still supported by the floor jack, remove the bolts connecting the lower control arm to the knuckle. There may be front and rear bolts or a single through-bolt depending on the specific suspension design. Lower the control arm away from the knuckle.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Remove hub and bearing assembly
   Remove the bolts securing the hub and bearing assembly to the rear of the knuckle (typically 3 or 4 bolts accessed from behind). Pull the hub assembly out of the knuckle. If stuck, use a slide hammer with hub adapter or carefully tap with a soft mallet.
10. 10

    Remove knuckle assembly
    With all connections removed, maneuver the knuckle assembly out of the wheel well. Inspect the new knuckle to ensure all mounting points match the original. Clean all mating surfaces on the control arms and suspension components with a wire brush and brake cleaner.
11. 11

    Install new knuckle
    Position the new knuckle into place in the wheel well. Install the hub and bearing assembly onto the knuckle from behind, threading in all mounting bolts finger-tight. Torque hub bolts to manufacturer specifications (typically 90-100 Nm) in a star pattern.
12. 12

    Reconnect lower control arm
    Raise the lower control arm with the floor jack and align it with the knuckle mounting points. Install the control arm bolts and thread them in finger-tight. Align any cam bolts to the marks made during disassembly. Do not torque these bolts yet - they must be torqued at ride height with vehicle weight on wheels.
    ℹ️Control arm bolts MUST be torqued with vehicle at normal ride height to prevent premature bushing failure.
    Torque spec

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

    Reconnect upper ball joint
    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 through the castle nut and ball joint stud, spreading the ends to secure.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
14. 14

    Reinstall shock absorber and sway bar link
    Raise the lower control arm with the floor jack to align the shock absorber lower mount. Install the shock bolt and torque to specification. Reconnect the sway bar link, holding the shaft with an Allen key while torquing the nuts.
    Torque spec

    Strut Bolts144 Nm (106 lb-ft)

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

    Reinstall ABS sensor and brake components
    Install the ABS wheel speed sensor into the knuckle and torque the mounting bolt. Route the wire and secure with retaining clips, then reconnect the electrical connector. Clean the hub surface and install the brake rotor. Remove the wire supporting the brake caliper and reinstall it over the rotor, torquing mounting bolts to specification.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
16. 16

    Install wheel and lower vehicle
    Install the wheel and thread lug nuts on by hand. Lower the vehicle until the tires just touch the ground but the suspension is still unloaded. Torque lug nuts to specification in a star pattern. Fully lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
17. 17

    Torque control arm bolts at ride height
    With the vehicle on the ground at normal ride height, crawl under and torque the lower control arm bolts to specification. This ensures proper bushing preload and prevents premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are tightened to proper torque specifications
2. Verify ABS sensor is properly connected and wire is secured
3. Check that brake caliper is properly mounted and brake hose is not kinked
4. Verify no tools or parts were left in the wheel well

Verification

• Pump brake pedal several times to ensure firm pedal feel before moving vehicle
• Test drive in a safe area at low speed to verify no unusual noises or vibrations
• Check for proper brake operation and ABS function
• Have alignment checked and adjusted at a qualified shop - knuckle replacement will affect camber, caster, and toe settings
• After 50-100 miles, re-check all fastener torques, especially control arm bolts and wheel lug nuts

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