This procedure covers the removal and replacement of both upper and lower ball joints on the front suspension of a 2015-2020 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Upper ball joint × 2 — Motorcraft or equivalent for F-150
• Lower ball joint × 2 — Motorcraft or equivalent for F-150
• Cotter pins × 4 — Use OEM specification
• Pinch bolt × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support on jack stands placed on frame rails
5. Remove front wheels completely
6. Spray all ball joint nuts, pinch bolts, and control arm fasteners with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Disconnect sway bar link
   Remove the sway bar link from the lower control arm. Hold the shaft with an Allen key to prevent rotation while loosening the nut. Support the lower control arm with a floor jack positioned under the control arm to take suspension load.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove brake caliper and rotor
   Remove the brake caliper mounting bolts and hang the caliper securely with wire or zip ties to prevent strain on the brake hose. Do not let caliper hang by the hose. Remove the brake rotor to provide access to the spindle and ball joint areas.
   ⚠Do not allow brake caliper to hang by the hydraulic hose as this can cause internal hose damage.
3. 3

   Remove wheel speed sensor
   Disconnect the ABS wheel speed sensor connector and remove the sensor mounting bolt. Carefully extract the sensor from the knuckle and secure it out of the way to prevent damage during ball joint service.
   ℹ️ABS sensors are fragile. Handle carefully and do not strike or bend the sensor tip.
4. 4

   Remove upper ball joint cotter pin and nut
   Remove the cotter pin from the upper ball joint castle nut using a cotter pin puller. Discard the old cotter pin. Loosen but do not fully remove the upper ball joint nut, leaving it on by a few threads to prevent the knuckle from dropping when the taper is released.
   Torque spec

   Ball Joint Nut117 Nm (86 lb-ft)
5. 5

   Separate upper ball joint from knuckle
   Use a ball joint separator or pickle fork to break the taper between the upper ball joint stud and the steering knuckle. Strike the separator tool sharply with a hammer. Once the taper is broken, remove the castle nut completely. Support the knuckle assembly to prevent it from falling.
   ⚠Use of a pickle fork will likely damage the ball joint boot. This is acceptable if replacing ball joints but avoid this method if reusing the joint.
6. 6

   Remove lower ball joint pinch bolt and separate
   Remove the pinch bolt that secures the lower ball joint to the steering knuckle. Discard the old pinch bolt as a new one must be installed. Use a pry bar or separator to spread the pinch joint and release the lower ball joint from the knuckle. The knuckle assembly can now be removed from the vehicle.
   ℹ️The pinch bolt is a torque-to-yield fastener and must be replaced with a new bolt during reassembly.
   Torque spec

   Pinch Bolt70 Nm (52 lb-ft)
7. 7

   Press out upper ball joint
   With the upper control arm removed or accessible, use a ball joint press kit with appropriate adapters to press the old upper ball joint out of the control arm. Position the press tool to push the ball joint through the control arm bore. Apply steady, even pressure until the ball joint is fully expelled. Clean the control arm bore with a wire brush.
   ⚠Ensure press adapters are correctly sized and properly aligned to prevent damage to the control arm or binding of the press tool.
8. 8

   Press in new upper ball joint
   Position the new upper ball joint in the control arm bore with the correct orientation (grease fitting accessible). Use the ball joint press with appropriate adapters to press the new ball joint into the control arm until it is fully seated against the shoulder. Ensure the ball joint is pressed in straight to avoid cocking or binding.
   ℹ️Verify the new ball joint is fully seated by checking that the flange is flush against the control arm surface around the entire circumference.
9. 9

   Press out lower ball joint
   Use a ball joint press kit to remove the old lower ball joint from the lower control arm. Position press adapters to support the control arm around the ball joint bore and press the ball joint out. Clean the control arm bore thoroughly with a wire brush to remove any corrosion or debris.
   ⚠The lower ball joint may require significant press force. Ensure the control arm is properly supported to prevent deformation.
10. 10

    Press in new lower ball joint
    Position the new lower ball joint in the control arm bore with proper orientation. Use the ball joint press to install the new lower ball joint, pressing it in until fully seated against the control arm shoulder. Verify complete seating by inspecting the flange contact all around.
    ℹ️Some lower ball joints may have orientation indicators or specific grease fitting positions. Verify correct installation orientation before pressing.
11. 11

    Install steering knuckle to lower ball joint
    Position the steering knuckle over the lower ball joint stud. Align the pinch bolt hole and install a new pinch bolt. Torque the pinch bolt to specification. Ensure the knuckle is fully seated on the ball joint taper.
    Torque spec

    Pinch Bolt70 Nm (52 lb-ft)
12. 12

    Connect upper ball joint to knuckle
    Raise the knuckle assembly and align the upper ball joint stud with the hole in the top of the knuckle. Install the castle nut on the upper ball joint and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends of the pin to secure.
    ℹ️If the cotter pin holes do not align after torquing, tighten the nut further (do not loosen) until the next castle slot aligns with the hole.
    Torque spec

    Ball Joint Nut117 Nm (86 lb-ft)
13. 13

    Reinstall brake components and wheel speed sensor
    Reinstall the ABS wheel speed sensor and secure the wiring. Install the brake rotor and remount the brake caliper to its bracket, torquing caliper bolts to specification. Verify the caliper moves freely and brake pads are properly positioned.
14. 14

    Reconnect sway bar link
    Connect the sway bar link to the lower control arm. Hold the link shaft with an Allen key and install the nut, torquing to specification. Remove the floor jack from under the control arm.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
15. 15

    Install wheels and lower vehicle
    Install the front wheels and thread lug nuts by hand. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Repeat the entire procedure for the opposite side if replacing both sides
2. After vehicle is on the ground with full weight on suspension, recheck all fastener torques, particularly control arm bolts if they were disturbed
3. Pump brake pedal several times to restore brake caliper piston position before moving vehicle
4. Grease all new ball joints through grease fittings if equipped with grease fittings

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises, vibrations, or steering issues
• Verify brake pedal feel is normal and brakes operate correctly
• Check for any fluid leaks around brake components
• Schedule a professional wheel alignment immediately, as ball joint replacement will alter suspension geometry and cause tire wear if not aligned
• After 50-100 miles, recheck all ball joint nuts and pinch bolt torque values

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