- Joined
- Aug 7, 2007
- Messages
- 1,728
- Reaction score
- 531
- Points
- 113
- Location
- Costa Mesa, CA
- Vehicle Year
- 2002
- Make / Model
- Ford
- Engine Type
- 4.0 V6
- Engine Size
- 4.0 SOHC
- Transmission
- Manual
- 2WD / 4WD
- 4WD
- Tire Size
- 33"
I just went through replacing my lower ball joints. I did a search to get tips on how to do it and it seems most people remove the caliper and hub to take on this project. I decided to see if there is a way to do it without removing the hub. It looked like removing the torsion bar and dropping the entire control arm would work. I then went to my Ford mechanics manual and sure enough that is what it shows to do. It also states the lower ball joint is not serviceable and to install a complete new lower control arm assembly.
Well, I had already bought a new set of Motorcraft ball joints and knew many people had replaced the lower ball joints so I proceeded to do it. Removing the lower control arm after removing the torsion bar was pretty straight forward and relatively quick. Unfortunately, I figured out pretty quick the ball joint was not easily pressed out of the control arm. I have a good press where I work so that was not a problem. Getting tools to fit the control arm and getting the control arm in the correct position was a problem. I have a full machine shop to make whatever I needed but the shape of the control arm makes it difficult to get even a custom tool to fit well. After over 6 hours I was able to get both ball joints pressed out and new ones pressed back in. It took between 5 and 7 tons force to do this. That is considerably more than I was expecting.
Knowing what I know now, I would have just replaced the entire control arm assembly like the Ford Manual stated. It would have cost me about 1.5 times more but I would also have new bushing which don't appear to be replaceable. My labor saved me about $25 an hour. I don't consider that a good deal.
I found that my torsion bar isolator on the right side was coming apart. It is right under the exhaust pipe and between two catalytic converters. I guess the heat got to the 'rubber' part of the isolator. Now I am waiting for that part to come in so I can finish assembly of the right side.
So, my suggestion for replacing the lower ball joints is to do it by removing the torsion bars and replacing the entire lower control arm assembly plus check out the torsion bar isolator's condition to see if it needs replacing. That way you can order it before starting the job and not have to wait on a part while your truck is down.
Well, I had already bought a new set of Motorcraft ball joints and knew many people had replaced the lower ball joints so I proceeded to do it. Removing the lower control arm after removing the torsion bar was pretty straight forward and relatively quick. Unfortunately, I figured out pretty quick the ball joint was not easily pressed out of the control arm. I have a good press where I work so that was not a problem. Getting tools to fit the control arm and getting the control arm in the correct position was a problem. I have a full machine shop to make whatever I needed but the shape of the control arm makes it difficult to get even a custom tool to fit well. After over 6 hours I was able to get both ball joints pressed out and new ones pressed back in. It took between 5 and 7 tons force to do this. That is considerably more than I was expecting.
Knowing what I know now, I would have just replaced the entire control arm assembly like the Ford Manual stated. It would have cost me about 1.5 times more but I would also have new bushing which don't appear to be replaceable. My labor saved me about $25 an hour. I don't consider that a good deal.
I found that my torsion bar isolator on the right side was coming apart. It is right under the exhaust pipe and between two catalytic converters. I guess the heat got to the 'rubber' part of the isolator. Now I am waiting for that part to come in so I can finish assembly of the right side.
So, my suggestion for replacing the lower ball joints is to do it by removing the torsion bars and replacing the entire lower control arm assembly plus check out the torsion bar isolator's condition to see if it needs replacing. That way you can order it before starting the job and not have to wait on a part while your truck is down.