This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2015-2020 Ford F-150 with 3.5L EcoBoost V6 engine, including separation from suspension components and wheel hub.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM specification or equivalent
• Lower ball joint nut (if not reusable) × 1 — Castle nut with cotter pin
• Tie rod end nut (if not reusable) × 1 — Castle nut with cotter pin
• Cotter pins × 3 — Various sizes as needed
• Anti-seize compound × 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 front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
4. Remove front wheel on side being serviced
5. Spray all fasteners to be removed with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove brake caliper assembly
   Remove the two brake caliper mounting bolts from the rear of the caliper bracket. Carefully remove the caliper and hang it securely from the frame or strut using a caliper hanger or wire. Do not allow the caliper to hang by the brake hose as this can damage the hose.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
2. 2

   Remove brake rotor
   Remove the brake rotor from the hub. If the rotor is stuck, use a rubber mallet to tap it loose. Some rotors may have retention screws that must be removed first. Set rotor aside in a clean area.
3. 3

   Disconnect ABS wheel speed sensor
   Locate the ABS wheel speed sensor connector at the back of the knuckle or in the wheel well. Press the release tab and disconnect the electrical connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Note the routing of the sensor wire for reinstallation.
4. 4

   Disconnect outer tie rod end
   Remove the cotter pin from the outer tie rod end castle nut. Remove the castle nut from the tie rod end stud. Use a tie rod end separator tool to separate the tie rod end from the steering knuckle. Do not strike the knuckle casting directly with a hammer as this may damage it.
   ⚠Tie rod separator can slip suddenly. Keep hands and face clear of the tool when applying force.
5. 5

   Disconnect stabilizer bar link
   Locate the stabilizer bar link connection at the lower control arm. Use an Allen key to hold the shaft of the link while removing the upper nut connecting it to the strut or lower control arm. Remove the link from the knuckle area.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
6. 6

   Remove strut-to-knuckle pinch bolts
   Locate the two large bolts securing the knuckle to the strut assembly. These are pinch-style bolts that clamp the knuckle to the strut. Support the knuckle assembly with one hand or a jack, then remove both strut-to-knuckle bolts. Note the orientation of any alignment cam washers if equipped.
   ⚠Support the knuckle before removing final fasteners to prevent it from falling.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
7. 7

   Disconnect lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Loosen but do not fully remove the castle nut. Use a ball joint separator tool to break the taper between the ball joint stud and the knuckle. Once the taper is broken, remove the nut completely. Note the stud orientation for reassembly.
   ⚠Keep the castle nut partially threaded during separation to prevent sudden release and potential injury.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
8. 8

   Remove knuckle assembly
   With all connections separated, carefully maneuver the knuckle assembly away from the strut and lower control arm. If the knuckle is stuck in the strut, gently pry or tap it loose using a plastic mallet. Remove the assembly from the vehicle. If the wheel hub and bearing are being transferred to the new knuckle, proceed with that operation now following manufacturer procedures.
   ℹ️Inspect the wheel hub bearing for noise, roughness, or play. Replace if necessary while knuckle is removed.
9. 9

   Prepare new knuckle
   Clean all mating surfaces on the new knuckle with a wire brush. If transferring the wheel hub, ensure it is properly pressed or bolted into the new knuckle per manufacturer specifications. Install the ABS wheel speed sensor into the new knuckle and secure with its mounting bolt. Apply a light coat of anti-seize to the ball joint taper seat and strut insertion area.
10. 10

    Install knuckle to lower ball joint
    Position the new knuckle onto the lower ball joint stud. Install the castle nut and tighten to specification. The nut must be tightened enough to allow cotter pin installation through the alignment holes. If the holes do not align, tighten further until they do - never loosen to align. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
11. 11

    Install knuckle to strut
    Align the knuckle with the strut housing, ensuring any alignment cams are properly oriented as noted during disassembly. Insert both strut-to-knuckle bolts and tighten to specification. Ensure the pinch joint is fully seated before final tightening.
    Torque spec

    Strut Bolts133 Nm (98 lb-ft)
12. 12

    Reconnect tie rod end and stabilizer link
    Install the outer tie rod end into the knuckle steering arm. Install the castle nut and tighten to specification, then install a new cotter pin. Reconnect the stabilizer bar link, holding the shaft with an Allen key while tightening the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Reinstall brake components
    Connect the ABS wheel speed sensor electrical connector, ensuring it clicks into place. Route the sensor wire as originally positioned. Install the brake rotor onto the hub, ensuring the mating surfaces are clean. Position the brake caliper over the rotor and install the caliper mounting bolts, tightening to specification.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
14. 14

    Install wheel and lower vehicle
    Install the wheel onto the hub and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground but the suspension is not yet 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. Verify all fasteners are properly torqued, especially safety-critical components like ball joints and tie rod ends
2. Ensure all cotter pins are properly installed and bent to prevent backing out
3. Check that the ABS sensor connector is fully seated and wire is properly routed away from moving components
4. Pump the brake pedal several times until firm before moving the vehicle

Verification

• Check brake fluid level in master cylinder reservoir and top off with Motorcraft DOT 4 LV brake fluid if necessary
• Test drive vehicle in a safe area at low speed to verify proper brake operation and absence of unusual noises
• Check for any fluid leaks around brake caliper connections
• Have front end alignment performed immediately, as suspension disassembly will affect toe and camber settings
• After 50-100 miles, re-torque wheel lug nuts to specification and verify all suspension fasteners remain tight

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