Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .

NOTE: The wheel speed sensor connectors are located in the engine compartment and are secured to the fender aprons.

Fig 1: Disconnecting Wheel Speed Sensor Connector

Courtesy of FORD MOTOR CO.

Disconnect the wheel speed sensor connector.
Remove the wheel and tire assembly. For additional information, refer to WHEELS AND TIRES .
Detach the harness from the retainers.

Fig 2: Locating Wheel Speed Sensor Harness And Brake Hose
Courtesy of FORD MOTOR CO.

CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide suitable support.

Remove the bolts and position the brake caliper and support bracket aside.
- To install, tighten to 112 Nm (83 lb-ft).
  
  Fig 3: Removing Bolts
  Courtesy of FORD MOTOR CO.
Remove the brake disc.

Fig 4: Removing Brake Disc
Courtesy of FORD MOTOR CO.
Remove and discard the cotter pin and the outer tie-rod end castellated nut.
- To install, tighten to 70 Nm (52 lb-ft).
  
  Fig 5: Discarding Cotter Pin
  Courtesy of FORD MOTOR CO.

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.

Fig 6: Separating Tie Rod From Wheel Knuckle

Courtesy of FORD MOTOR CO.

Using the special tool, separate the tie rod from the wheel knuckle.
Remove and discard the cotter pin and the lower ball joint castellated nut.
- To install, tighten to 150 Nm (111 lb-ft).
  
  Fig 7: Discarding Cotter Pin
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use a hammer to separate the ball joint from the wheel knuckle or damage to the wheel knuckle will result.

Fig 8: Separating Lower Ball Joint From Wheel Knuckle

Courtesy of FORD MOTOR CO.

Using the special tool, separate the lower ball joint from the wheel knuckle. Reinstall and hand-tighten the lower ball joint castellated nut.
Remove and discard the upper ball joint nut.
- To install, tighten to 55 Nm (41 lb-ft).
  
  Fig 9: Discarding Upper Ball Joint Nut
  Courtesy of FORD MOTOR CO.

CAUTION: Do not use a hammer to separate 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.

Fig 10: Separating Upper Ball Joint From Wheel Knuckle

Courtesy of FORD MOTOR CO.

Using the special tool, separate the upper ball joint from the wheel knuckle.
Remove the hand-tightened lower ball joint castellated nut and remove the wheel knuckle.
Remove and discard the snap ring from the ball joint.

Fig 11: Discarding Snap Ring From Ball Joint
Courtesy of FORD MOTOR CO.
Using a suitable ball joint remover tool, remove the ball joint.

Fig 12: Removing Ball Joint
Courtesy of FORD MOTOR CO.

CAUTION: Do not damage the ball joint boot when installing the special tool.

NOTE: 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 seated.

To install, reverse the removal procedure.
- Always install new:
  - snap rings.
  - castellated nuts.
  - cotter pins.
  - upper ball joint nuts.