This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine, including disconnection of brake components, wheel speed sensor, and ball joints.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Wheel hub bearing (if not included with knuckle) × 1 — Use OEM specification
• Upper ball joint cotter pin × 1 — Use OEM specification
• Lower ball joint cotter pin × 1 — Use OEM specification
• Brake caliper mounting bolts (if damaged) × 2 — Use OEM specification
• Anti-seize compound × 1 — Use high-temperature rated

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Loosen wheel lug nuts 1/4 turn while vehicle is on ground.
3. Raise front of vehicle and support securely on jack stands at frame rails.
4. Remove wheel and tire assembly completely.
5. Spray all ball joint nuts, strut bolts, and brake caliper bolts with penetrating lubricant and allow to soak for 10-15 minutes.
6. Place drain pan under work area to catch any brake fluid spillage.

Procedure

1. 1

   Remove brake caliper
   Remove the two brake caliper mounting bolts from the back of the knuckle. Slide the caliper off the rotor and support it with a wire hanger or caliper hanger attached to the strut spring. Do not let the caliper hang by the brake hose. If additional clearance is needed, the brake hose can be disconnected from the caliper (this will require brake bleeding).
   Torque spec

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

   Remove brake rotor and ABS sensor
   Remove the brake rotor by pulling it straight off the hub. If stuck, use two M8 bolts in the threaded holes to push it off. Disconnect the wheel speed sensor electrical connector and remove the sensor mounting bolt. Carefully extract the ABS sensor from the knuckle and secure it out of the way to prevent damage.
3. 3

   Disconnect sway bar link
   Locate the sway bar end link attached to the lower control arm. Hold the shaft with an Allen key to prevent rotation and remove the upper nut connecting the link to the lower control arm. Swing the link out of the way.
   Torque spec

   Sway Bar Link76 Nm (56 lb-ft)
4. 4

   Remove strut-to-knuckle bolts
   Support the lower control arm with a floor jack to maintain suspension position. Remove the two bolts connecting the strut to the knuckle. These are through-bolts that pass horizontally through the strut bracket on the knuckle. Note the orientation of any alignment cams or washers for reassembly.
   ⚠Support the lower control arm before removing strut bolts to prevent sudden suspension drop.
   Torque spec

   Strut Bolts144 Nm (106 lb-ft)
5. 5

   Separate upper ball joint
   Remove the cotter pin from the upper ball joint castle nut and discard. Remove the castle nut completely. Use a ball joint separator tool or pickle fork to separate the upper ball joint stud from the knuckle. Position the separator between the upper control arm and the knuckle, then strike with a hammer or use the threaded forcing screw until the taper releases.
   ⚠The knuckle will become loose once both ball joints are separated. Ensure it is supported or controlled to prevent sudden movement.
   Torque spec

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

   Separate lower ball joint
   Remove the cotter pin from the lower ball joint castle nut and discard. Remove the castle nut completely. Use the ball joint separator tool to break the taper between the lower ball joint stud and the knuckle. Apply force carefully as the knuckle will be free once this joint separates.
   Torque spec

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

   Remove knuckle assembly
   With both ball joints separated and strut disconnected, carefully maneuver the knuckle assembly away from the vehicle. The hub and bearing may come with it depending on your replacement part configuration. Inspect the ball joint tapers in the knuckle for damage or excessive wear.
8. 8

   Transfer components to new knuckle
   If the new knuckle does not include the hub bearing, you will need to press out the old bearing from the old knuckle and press it into the new knuckle (this requires a hydraulic press and is often done at a machine shop). If replacing the complete assembly, verify the ABS tone ring is present on the new hub. Clean all mating surfaces with a wire brush.
9. 9

   Install knuckle to ball joints
   Apply a small amount of anti-seize to the ball joint studs (avoid getting any on the tapered surfaces). Position the new knuckle onto the lower ball joint stud first, then raise it to engage the upper ball joint stud. Thread on both castle nuts hand-tight. Torque the ball joint nuts to specification, then advance to the next castle slot if needed to align the cotter pin hole. Install new cotter pins and bend the ends to secure.
   ℹ️Never back off a castle nut to align the cotter pin hole. Only advance (tighten) to the next slot.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
10. 10

    Reconnect strut to knuckle
    Align the knuckle with the strut bracket. Install the two strut-to-knuckle through-bolts, ensuring any alignment cams or washers are in their original positions. Torque bolts to specification while maintaining the lower control arm support with the floor jack.
    Torque spec

    Strut Bolts144 Nm (106 lb-ft)
11. 11

    Reinstall sway bar link
    Reconnect the sway bar end link to the lower control arm. Hold the shaft with an Allen key and torque the nut to specification.
    Torque spec

    Sway Bar Link76 Nm (56 lb-ft)
12. 12

    Install ABS sensor, rotor, and caliper
    Install the ABS wheel speed sensor into the knuckle and secure with its mounting bolt. Reconnect the electrical connector. Clean the hub surface and install the brake rotor. Position the brake caliper over the rotor and install the caliper mounting bolts. Torque to specification. If the brake hose was disconnected, bleed the brake system.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread lug nuts on by hand, then snug them in a star pattern. Lower the vehicle until the tire just contacts the ground but suspension is not fully loaded. Torque wheel lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Torque control arm bolts with vehicle weight on suspension as specified if any were loosened during the procedure.
2. Check brake fluid level in master cylinder reservoir and top off with DOT 4 LV fluid if needed.
3. If brake hose was disconnected, perform proper brake bleeding procedure on the affected corner.

Verification

• Test brake pedal feel before moving vehicle. Pedal should be firm and not sink to the floor.
• Perform a visual inspection of all connections to ensure bolts are tight and cotter pins are installed.
• Test drive vehicle at low speed in a safe area and verify no unusual noises or vibrations from the front suspension.
• Check for proper steering response and verify no pulling to either side during braking.
• Schedule a professional wheel alignment as this procedure will affect camber and toe settings.

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