This procedure covers the removal and replacement of the rear knuckle/spindle assembly on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine, including disconnection of suspension components, brake components, and wheel hub.

Warnings

Tools required

Parts

• Rear knuckle/spindle assembly × 1 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification
• Brake rotor (if damaged during removal) × 1 — Use OEM specification

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 contact points
4. Remove rear wheel on affected side
5. Spray all fasteners with penetrating lubricant and allow to soak
6. Position floor jack under rear axle or control arm for controlled lowering of suspension

Procedure

1. 1

   Remove brake caliper
   Remove the two brake caliper mounting bolts and carefully slide the caliper off the rotor. Support the caliper with wire or a caliper hanger to prevent stress on the brake hose. Do not let the caliper hang by the brake line.
   Torque spec

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

   Remove brake rotor
   Remove the brake rotor from the hub. If rotor is seized, use penetrating lubricant and light tapping with a hammer. If rotor has set screws, remove them first. Inspect rotor for damage and replace if necessary.
3. 3

   Disconnect sway bar link
   Locate the sway bar link connection at the knuckle or control arm. Hold the link shaft with an Allen key to prevent spinning, then remove the sway bar link nut. Separate the link from the mounting point.
   Torque spec

   Sway Bar Link71 Nm (52 lb-ft)
4. 4

   Disconnect lower ball joint
   Remove the cotter pin from the lower ball joint castle nut using a cotter pin puller. Remove the ball joint nut. Use a ball joint separator tool to press the ball joint stud from the knuckle. Apply pressure gradually to avoid damaging the threads or knuckle.
   ⚠Do not strike the ball joint stud with a hammer as this can damage the stud or knuckle taper.
   Torque spec

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

   Support knuckle assembly
   Position a floor jack or support under the knuckle assembly to control its movement during strut disconnection. The knuckle will drop when the strut bolts are removed.
6. 6

   Remove strut-to-knuckle bolts
   Locate the two strut mounting bolts connecting the strut to the knuckle. Remove both bolts while supporting the knuckle. The knuckle may need to be pulled outward slightly to clear the strut mounting bracket.
   Torque spec

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

   Disconnect ABS sensor if equipped
   If the vehicle is equipped with wheel speed sensors mounted to the knuckle, disconnect the electrical connector and remove the sensor mounting bolt. Carefully remove the sensor from the knuckle to prevent damage.
   ⚠ABS wheel speed sensors are fragile. Do not pull on the wire and avoid bending the sensor tip.
8. 8

   Remove wheel hub and bearing if necessary
   If the wheel hub and bearing are to remain with the old knuckle, remove the hub mounting bolts from the rear of the knuckle. If the hub is to be transferred to the new knuckle, use a hub puller or press to separate it. Mark the orientation of the hub before removal for proper reinstallation.
9. 9

   Remove knuckle from vehicle
   With all connections disconnected, remove the knuckle assembly from the vehicle. Inspect all mounting surfaces on the vehicle for damage, corrosion, or debris. Clean mounting surfaces with a wire brush.
10. 10

    Prepare new knuckle
    Compare the new knuckle to the old unit to verify correct application. Transfer any components from the old knuckle to the new one as necessary (wheel hub, backing plate, etc.). Clean all mounting surfaces and apply a thin coat of anti-seize to ball joint taper and strut mounting surfaces.
11. 11

    Install knuckle to strut
    Position the new knuckle onto the strut mounting bracket. Install both strut-to-knuckle bolts and hand-tighten. Do not fully torque at this time as suspension must be at ride height for final torquing.
    Torque spec

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

    Connect lower ball joint
    Align the lower ball joint stud with the knuckle taper. Install the ball joint castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, then bend the pin legs to secure.
    Torque spec

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

    Reconnect sway bar link
    Position the sway bar link into its mounting point on the knuckle or control arm. 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 ABS sensor if equipped
    If removed, reinstall the wheel speed sensor into the knuckle bore. Ensure the sensor is fully seated and the mounting hole aligns. Install the sensor mounting bolt and tighten securely. Reconnect the electrical connector.
15. 15

    Install brake rotor and caliper
    Install the brake rotor onto the wheel hub. Position the brake caliper over the rotor and install the caliper mounting bolts. Torque the mounting bolts to specification. Pump the brake pedal several times to seat the pads before moving the vehicle.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

Reassembly

1. Install the wheel and hand-tighten lug nuts in a star pattern
2. Lower the vehicle until the suspension is at normal ride height but wheels are not fully supporting vehicle weight
3. Torque the strut-to-knuckle bolts to specification with suspension at ride height
4. Lower vehicle completely to ground
5. Torque wheel lug nuts to specification in a star pattern
6. If control arm bolts were loosened during the procedure, torque them with vehicle weight on wheels at normal ride height

Verification

• Test drive vehicle at low speed and verify no abnormal noises from rear suspension
• Verify brake pedal feels firm and brakes operate normally
• Check for proper wheel alignment - vehicle should track straight without pulling
• Have a professional wheel alignment performed as suspension geometry has been altered
• Verify ABS warning light does not illuminate on dashboard if sensor was disconnected
• Inspect all fasteners after 50-100 miles to ensure none have loosened

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