892019 ball-joint-8212-lower-2wd-removal-and-installationpdf

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204-00-1 204-00-1Suspension System

REMOVAL AND INSTALLATION

3 Remove the wheel and tire assembly ForBall Joint mdash Lower 2WDadditional information refer to Wheel and Tire

mdash Front in this sectionSpecial Tool(s)

InstallerRemover C-Frame and 4 Detach the harness from the retainers

Screw211-023 (T74P-3044-A1)

Remover Steering Arm211-003 (T64P-3590-F)

InstallerRemover C-Frame andScrew 5 CAUTION Do not allow the disc205-086 (T74P-4635-C) brake caliper to hang suspended from the

brake hose Provide suitable support

Remove the bolts and position the brake caliper

and support bracket aside

Removal and Installation

1 With the vehicle in NEUTRAL position it on a

hoist For additional information refer to

Section 100-00

2 NOTE The wheel speed sensor connectors are

located in the engine compartment and are

secured to the fender aprons

Disconnect the wheel speed sensor connector

Copyright 983209 2002 Ford Motor CompanyLast updated 1292004 2003 ExplorerMountaineer 92002

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204-00-2 204-00-2Suspension System

REMOVAL AND INSTALLATION (Continued)

6 Remove the brake disc 9 Remove and discard the cotter pin and the

castellated nut

7 Remove and discard the cotter pin and the

castellated nut 10 CAUTION Do not use a hammer to

separate the ball joint from the wheelknuckle or damage to the wheel knuckle will

result

Using the special tool separate the lower ball

joint from the wheel knuckle Reinstall and

hand-tighten the lower ball joint castellated nut

8 CAUTION Do not use a hammer to

separate the tie-rod from the wheel knuckle

or damage to the wheel knuckle will result

CAUTION Do not damage the tie-rod

boot when installing the special tool

Using the special tool separate the tie-rod from11 Remove and discard the upper ball joint nut

the wheel knuckle

2003 ExplorerMountaineer 92002

892019 ball-joint-8212-lower-2wd-removal-and-installationpdf

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204-00-3 204-00-3Suspension System

REMOVAL AND INSTALLATION (Continued)

15 Using a suitable ball joint remover tool remove12 CAUTION Do not use a hammer tothe ball jointseparate the ball joint from the wheel

knuckle or damage to the wheel knuckle will

result

CAUTION Do not damage the ball

joint boot when installing the special tool

Using the special tool separate the upper ball

joint from the wheel knuckle

16 CAUTION Do not damage the ball

joint boot when installing the special toolNOTE Clean and inspect the control arm ball

joint bore for damage before installing a new

ball joint

NOTE Make sure the new ball joint snap ring

is fully seated13 Remove the hand-tightened lower ball joint

castellated nut and remove the wheel knuckle To install reverse the removal procedure

bull Always install new castellated nuts and14 Remove the snap ring from the ball joint

cotter pinsDiscard the snap ring

2003 ExplorerMountaineer 92002

892019 ball-joint-8212-lower-2wd-removal-and-installationpdf

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204-00-2 204-00-2Suspension System

REMOVAL AND INSTALLATION (Continued)

6 Remove the brake disc 9 Remove and discard the cotter pin and the

castellated nut

7 Remove and discard the cotter pin and the

castellated nut 10 CAUTION Do not use a hammer to

separate the ball joint from the wheelknuckle or damage to the wheel knuckle will

result

Using the special tool separate the lower ball

joint from the wheel knuckle Reinstall and

hand-tighten the lower ball joint castellated nut

8 CAUTION Do not use a hammer to

separate the tie-rod from the wheel knuckle

or damage to the wheel knuckle will result

CAUTION Do not damage the tie-rod

boot when installing the special tool

Using the special tool separate the tie-rod from11 Remove and discard the upper ball joint nut

the wheel knuckle

2003 ExplorerMountaineer 92002

892019 ball-joint-8212-lower-2wd-removal-and-installationpdf

httpslidepdfcomreaderfullball-joint-8212-lower-2wd-removal-and-installationpdf 33

204-00-3 204-00-3Suspension System

REMOVAL AND INSTALLATION (Continued)

15 Using a suitable ball joint remover tool remove12 CAUTION Do not use a hammer tothe ball jointseparate the ball joint from the wheel

knuckle or damage to the wheel knuckle will

result

CAUTION Do not damage the ball

joint boot when installing the special tool

Using the special tool separate the upper ball

joint from the wheel knuckle

16 CAUTION Do not damage the ball

joint boot when installing the special toolNOTE Clean and inspect the control arm ball

joint bore for damage before installing a new

ball joint

NOTE Make sure the new ball joint snap ring

is fully seated13 Remove the hand-tightened lower ball joint

castellated nut and remove the wheel knuckle To install reverse the removal procedure

bull Always install new castellated nuts and14 Remove the snap ring from the ball joint

cotter pinsDiscard the snap ring

2003 ExplorerMountaineer 92002

892019 ball-joint-8212-lower-2wd-removal-and-installationpdf

httpslidepdfcomreaderfullball-joint-8212-lower-2wd-removal-and-installationpdf 33

204-00-3 204-00-3Suspension System

REMOVAL AND INSTALLATION (Continued)

15 Using a suitable ball joint remover tool remove12 CAUTION Do not use a hammer tothe ball jointseparate the ball joint from the wheel

knuckle or damage to the wheel knuckle will

result

CAUTION Do not damage the ball

joint boot when installing the special tool

Using the special tool separate the upper ball

joint from the wheel knuckle

16 CAUTION Do not damage the ball

joint boot when installing the special toolNOTE Clean and inspect the control arm ball

joint bore for damage before installing a new

ball joint

NOTE Make sure the new ball joint snap ring

is fully seated13 Remove the hand-tightened lower ball joint

castellated nut and remove the wheel knuckle To install reverse the removal procedure

bull Always install new castellated nuts and14 Remove the snap ring from the ball joint

cotter pinsDiscard the snap ring

2003 ExplorerMountaineer 92002