This procedure covers the replacement of both upper and lower ball joints on the front suspension of a 2021-2024 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Upper ball joint (per side) × 2 — Use OEM or Moog K500368 equivalent
• Lower ball joint (per side) × 2 — Use OEM or Moog K500367 equivalent
• Cotter pins × 4 — Use OEM specification
• Pinch bolt (if reusable bolt is damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
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 and control arm bolts with penetrating oil and allow to soak for 15-20 minutes
6. Verify you have correct replacement ball joints for upper and lower positions before beginning disassembly

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connecting the sway bar to the lower control arm. Hold the link shaft with an Allen key to prevent rotation, then remove the lower sway bar link nut. Swing the sway bar link up and away from the control arm to provide working clearance.
   Torque spec

   Sway Bar Link71 Nm (52 lb-ft)
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint where it connects to the steering knuckle. Use a cotter pin puller or pliers to remove and discard the cotter pin from the castle nut. Using a socket and breaker bar, remove the upper ball joint castle nut completely. Do not allow the knuckle to drop when nut is removed.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
3. 3

   Separate upper ball joint from knuckle
   Position a ball joint separator (pickle fork) between the upper control arm and steering knuckle at the ball joint taper. Strike the separator firmly with a hammer to break the taper fit. Alternatively, use a ball joint puller tool if available. Once separated, support the knuckle assembly to prevent strain on the lower ball joint and CV axle.
   ⚠The pickle fork method will damage the ball joint boot. This is acceptable since you are replacing the ball joint.
4. 4

   Remove lower ball joint cotter pin and nut
   Remove the cotter pin from the lower ball joint castle nut and discard it. Remove the lower ball joint nut completely. Support the steering knuckle and brake assembly with a jack or support stand to prevent it from dropping.
   Torque spec

   Ball Joint Nut102 Nm (75 lb-ft)
5. 5

   Separate lower ball joint and remove knuckle
   Use the ball joint separator to break the taper fit between the lower ball joint and steering knuckle, similar to the upper joint. Once separated, carefully maneuver the steering knuckle, brake caliper, and rotor assembly away from the control arms. You may need to disconnect the outer tie rod end if clearance is insufficient. Support the assembly out of the way with wire or a bungee cord.
   ⚠Do not let the brake caliper hang by the brake hose. Support it with wire or place on a stand.
6. 6

   Remove upper control arm (if necessary)
   If the upper ball joint is pressed into the upper control arm and requires removal for pressing, remove the upper control arm mounting bolts from the frame. Note the position and orientation of any alignment shims or cams for reinstallation. Remove the control arm from the vehicle and take to your press or workbench.
   ℹ️Mark or photograph alignment cam positions before removal to maintain approximate alignment settings.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Press out old upper ball joint
   Using a ball joint press or hydraulic press, position the upper control arm in the press with proper adapters supporting the control arm around the ball joint. Press the old ball joint out of the control arm bore. Clean the bore thoroughly with a wire brush, removing all dirt, rust, and debris. Inspect the bore for damage.
   ⚠Ensure press adapters are properly sized and centered to avoid damaging the control arm.
8. 8

   Press in new upper ball joint
   Position the new upper ball joint in the control arm bore, ensuring it is properly oriented (grease fitting accessible if applicable). Using the ball joint press with appropriate adapters, press the new ball joint into the control arm until it is fully seated. The ball joint should be flush or seated to the manufacturer's specified depth. Verify the ball joint moves freely in its socket.
   ℹ️Some ball joints have a specific installation depth or require a snap ring. Consult the ball joint manufacturer's instructions.
9. 9

   Remove and replace lower ball joint
   Repeat the pressing procedure for the lower ball joint. Remove the lower control arm from the vehicle if necessary by removing the control arm mounting bolts. Press out the old lower ball joint, clean the bore, and press in the new lower ball joint using the same careful procedure. Ensure proper orientation and full seating.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
10. 10

    Reinstall control arms (if removed)
    If control arms were removed, reinstall them to the frame using the original mounting bolts. Position any alignment cams or shims in their original positions. Thread bolts finger-tight only at this stage. Final torque will be applied with vehicle weight on the suspension.
    ℹ️Control arm bolts must be torqued at ride height with vehicle weight on wheels.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Reconnect steering knuckle to ball joints
    Position the steering knuckle assembly back onto the lower ball joint stud, then align the upper ball joint stud into the upper knuckle bore. Install the lower ball joint castle nut and tighten to specification. Install the upper ball joint castle nut and tighten to specification. Ensure the castle nut slots align with the ball joint stud cotter pin holes.
    ℹ️If castle nut slots do not align with cotter pin hole, tighten nut slightly more (never loosen) until alignment is achieved.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)
12. 12

    Install new cotter pins
    Insert new cotter pins through the ball joint studs and castle nuts. Bend the cotter pin ends around the nut to secure. Ensure cotter pins are properly seated and cannot back out. Verify both upper and lower ball joints are secure.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)
13. 13

    Reconnect sway bar link
    Position the sway bar link back onto the lower control arm mounting point. Install the sway bar link nut while holding the shaft with an Allen key to prevent rotation. Torque to specification.
    Torque spec

    Sway Bar Link71 Nm (52 lb-ft)
14. 14

    Reinstall wheels and lower vehicle
    Install the front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but the suspension is not yet loaded. Torque wheel lug nuts to specification in a star pattern. Fully lower the vehicle to the ground.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
15. 15

    Final torque control arm bolts at ride height
    With the vehicle on the ground at normal ride height, torque all control arm mounting bolts that were loosened or removed to the specified torque. This ensures proper bushing alignment and longevity. Bounce the suspension several times before final torquing to settle components.
    ℹ️Torquing suspension bushings at ride height is critical to prevent premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all cotter pins are properly installed and secured on both sides
2. Verify all fasteners have been torqued to specification
3. Control arm bolts must be torqued with vehicle weight on suspension at ride height

Verification

• Check that all ball joint castle nuts are torqued properly and cotter pins are installed
• Verify there is no excessive play in the new ball joints by attempting to move the wheel up and down with vehicle raised
• Test drive the vehicle at low speed and verify normal steering feel with no clunking or looseness
• Have the front end alignment checked and adjusted by a professional alignment shop as soon as possible after this repair

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