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A more comprehensive description would have been helpful - you know what you mean but in order for us to fully understand the suspension type and system and the problem you need to paint an accurate picture with words.
Wherever possible the manufacturer designs the suspension with the maximum safety in mind so the only way a ball joint can pop out of a suspension arm is where there is damage or replacement has been botched.
Do you mean the ball pin is popping out of the joint? If this is what is happening the joint is damaged or worn out and immediate replacement is necessary.
According to Autozone.com, you must replace the whole control arm. Here is their procedure: NOTE
do not begin the removal procedure unless a new strut-to-lower arm nut, a new ball joint pinch bolt/nut and a new lower arm-to-front subframe bolt/nut are available.
Remove or disconnect the following:
NOTE
Do not use a hammer to separate the ball joint from the front wheel hub and spindle.
WheelsLower arm strut nut and dished washer. Discard them.
Place the steering wheel in the unlocked position.
NOTE
Do not allow the halfshaft to move outward. Over-extension of the halfshaft joint could result in separation of internal parts, causing failure of the halfshaft joint.
Remove or disconnect the following:
NOTE
Use extreme care to not damage the ball joint boot seal.
Lower arm ball joint nut and pinch bolt. Discard them.Lower arm from the front wheel knuckle
Remove and discard the lower arm-to-front subframe bolt and nutRemove the lower arm from the vehicleTo install:
Install or connect the following:
Lower arm strut into the lower arm rear strut bushingLower arm into the front sub-frame bracketNew lower arm-to-front subframe nut and bolt. While holding the lower arm horizontal, tighten to 85-97 ft. lbs. (115-132 Nm).Ball joint stud-to-wheel hub and spindle, making sure that the ball stud groove is properly positioned.New lower arm ball joint pinch bolt and nut. Tighten to 46-52 ft. lbs. 62-71 Nm).
Clean the lower arm strut threads to remove dirt and contamination.
Install the dished washer with the dished side away from the lower arm rear strut bushing.
Install the front suspension lower arm strut-to-strut nut and tighten to 85-97 ft. lbs. (115-142 Nm).
Raise the front of the vehicle and install safety stands.
Remove the wheel and tire assembly. Refer to Section 04-04 .
Remove the disc brake caliper (2B120) from the rotor and wire it out of the way. Refer to Section 06-03 .
Remove the dust cap, cotter pin, nut retainer, nut, washer and front wheel bearing (1216).
Remove the rotor from the front wheel spindle (3105).
Item
Part Number
Description
1
606085
Clamp Bolt
2
3B404
Camber Adjuster
3
800895
Nut
4
800937
Nut
5
3049
Front Suspension Upper Ball Joint
6
3050
Front Suspension Lower Arm Ball Joint
7
3105
Front Wheel Spindle
8
642569
Cotter Pin
9
3304
Steering Sector Shaft Arm Drag Link
10
383489
Nut
11
3001
Front Axle Assembly
12
388727
Bolt
A
-
Tighten to 77-103 Nm (57-75 Lb-Ft)
B
-
Tighten to 68-92 Nm (50-67 Lb-Ft)
C
-
Tighten to 113-153 Nm (83-112 Lb-Ft)
D
-
Tighten to 340-460 Nm (250-339 Lb-Ft)
Remove bearing cone and roller (1201) and wheel hub grease seal (1190). Discard the seal.
Remove front disc brake rotor shield (2K004). Refer to Section 06-03 .
Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with Tie Rod End Remover TOOL-3290-D or equivalent.
Remove the cotter pin and castellated nut from the lower ball joint stud.
Remove the nut from the axle clamp bolt and remove the bolt from the axle.
Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool D81T-3010-B or equivalent to remove adjuster.
CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket.
Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam.
Remove the front wheel spindle and ball joint from the axle.
Ball Joint, F-150, F-250, F-350
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Tool Number
U-Joint Tool
T74P-4635-C
Ball Joint Remover
T94T-3010-AH Removal
Remove the front wheel spindle (3105) and ball joint assembly from the axle. Refer to Wheel Spindle, F-150, F-250, F-350 in the Removal and Installation portion of this section.
NOTE: Lower ball joint must be removed first.
Install the front wheel spindle in a vise and remove the snap ring from the lower ball joint.
Remove the lower ball joint from the front wheel spindle using U-Joint Tool T74P-4635-C and Receiver Cup D81T-3010-A5 or equivalent for F-150. Use Ball Joint Remover T94T-3010-AH for F-250 and F-350.
Turn the forcing screw clockwise until the ball joint is removed from the front wheel spindle.
CAUTION: Do not heat the ball joint or the front wheel spindle to aid in removal.
Assemble U-joint tool and cup on the upper ball joint, and turn forcing screw clockwise until ball joint is removed from the front wheel spindle.
Installation
CAUTION: Do not heat the ball joint or axle to aid in installation. NOTE: Upper ball joint must be installed into the front wheel spindle first.
NOTE: Individual ball joint tools are included in Ball Joint Adapter Set D81T-3010-A or equivalent.
To install the upper ball joint, assemble C-frame assembly, Ball Joint Receiver Cup D81T-3010-A5 and Installation Cup D81T-3010-A1 and D81T-3010-A3 or equivalents inside cup D81T-3010-A4 or equivalent in position on the front wheel spindle.
Turn forcing screw clockwise until ball joint is seated.
You'll need the repair manual for this. There are upper and lower ball joints front and rear. You also have to deal with a number of suspension components to access the ball joints. Lower ball joints can be replaced by pressing old out and new in using a large socket to match circumference of the ball joint.
Before servicing the vehicle, refer to the precautions in the beginning of this section.
Remove or disconnect the following:
Wheel and tire assembly
Brake disc shield
Use a jack to support the front suspension lower arm.
Mark the position of the front suspension upper arm adjustment cams.
Remove the upper ball joint retaining nut and pinch bolt.
Separate the ball joint from the front wheel spindle
Remove the front suspension upper control arm.
To Install:
Installation is the reverse of removal. Align the marks made during removal on the front suspension upper arm adjustment cam. The forward front suspension upper arm nut must be tightened first while the arm is held at the curb position ride height.
For That you use a C-clamp style ball joint press to remove the ball joint from the suspension arm-note the location of the receiver cup ! For installation of the ball-joint, use the same tool when pressing the ball joint into the suspension arm-again, note the location of the receiver cup.
Step by Step :
Raise and support the vehicle safely, with jackstands.
Remove the spindle and the ball joint assembly from the vehicle.
Remove the snapring from the ball joint. Using a ball joint removal tool, remove the ball joint from the spindle. Do not heat the ball joint or the axle to aid in removal.
Installation is the reverse of the removal procedure. Torque the ball joint stud nut to 85-110 ft. lbs. for 1983-89 Ranger and Bronco II.
Your going to have some tension on the lower control arm, so be aware if the danger. When i replaced the ball joints on my Jimmy, i had it up on a stand and then placed the jack under the control arm to support it so i can let it down slowly.
Once the new ball joint is in place, i used the jack to bring up the control arm again to line it up with the spindle to put the front suspension together again.
Thank you for using Fixya and be safe.
The front suspension on this car should have struts, which means it will have two ball joints, one on each side. They are in the lower control arm, they connect the front bearing spindle to the lower control arm. They can be difficult to replace, some are bolted and some are press fitted. Any reputable front end alignment shop can replace these, but the cost for doing the job will be more expensive for the press fit ball joints. Hope this helps, let me know.
Inspect lower ball joint boots and seals for damage and replace if required. Lower ball joint and seal is part of front suspension lower arm and must be replaced as an assembly.
NOTE: Do not tighten the front suspension lower arm bolts and nuts to the specified torque until the end of assembly. Install nuts and tighten until snug.
Position the front suspension lower arm in the front crossmember. Install the bolts. Install the nuts and tighten until snug.
Install torsion bar. Refer to Torsion Bar in this section.
Raise the front suspension lower arm to allow installation of front suspension lower arm ball joint into spindle bore.
Lower front suspension lower arm with a jack while making sure lower ball joint is seated in spindle bore. Install the lower ball joint attaching nut and tighten to 113-153 Nm (82-113 lb-ft). Install a new cotter pin.
Raise vehicle. Position the front shock absorber and install the nut/washer/bushing assembly. Tighten nut to 40-55 Nm (30-40 lb-ft).
Install the two nuts attaching the front shock absorber to the lower control arm and tighten to 21-29 Nm (15-21 lb-ft).
NOTE: Front suspension lower arms must be in the horizontal or curb position (vehicle on the ground) when tightening the front stabilizer bar link bolts. Use jackstands to raise the front suspension lower arms to the horizontal position or lower the vehicle to the ground (curb position).
Lower the vehicle to the ground.
Connect the stabilizer bar link bolt to the front suspension lower arm and tighten to 13-17 Nm (10-13 lb-ft).
Tighten nuts and front suspension lower arm bolts to the No. 1 crossmember to 150-200 Nm (111-148 lb-ft).
Check ride height and align as necessary. Refer to Section 04-00 .
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