I have just noticed that the bellows-like plastic seals around the upper ball joints on my 2003 4x2 Expy are cracking all around the joint and letting grease out. The vehicle does not see much wet weather at all and there doesn't seem to be any looseness in the joints, so just repairing the seals after throwing a little more grease in them would be the most cost-effective plan, rather than replace the upper control arms as the joints aren't serviceable (Thanks, Ford).

What is a good repair? A bicycle tube?

 

You cannot guarantee that water or dirt has not already entered the ball joint. Replacing the ball joint is really the only way to go.

 

Yes, I know. 1100 bucks at Ford. However, I have examined what I can see, and it has zero moisture or rust and no play. Assuming that the joint is sound, what is a cost effective seal repair? Can I apply some sort of rubber sealing compound?

 

Have the lower ball joints ever been replaced ? Because that's where the load bearing takes place. If the boots are cracked and torn I can pretty much guarantee you the bottoms are worn out. You can get the parts from Rock Auto for far less than the dealer. There's really no load on the upper ball joints other than a side load, but the lowers carry the weight and wear out after about 100k miles. Also inspect the inner tie rods. They're good for about 75k miles.
I'd use some of that bright orange liquid electrical tape if you really don't want to buy replacement dust boots for the uppers .


-Mike

 

I changed the uppers on my Dodge van with 120K a few years back. The thing was handling really poorly. The suspension shop said the the lowers were OK at then time. He said the lowers will wear, but since the load is on them there is no handling difference, and to change them at 200K. The lower joints on this Expy aren't leaking at all, so I would think that they should be good for a little while. The car hardly gets used these days and new ball joints are more than the budget will allow.

 

Rockauto sells complete upper control arms for $62 from Moogs pr piece, so if you have the wrenching skills and tools to do the job, then it won't cost you much at all to replace it.

 

Thanks, that's the lowest I have seen. I will probably tackle them during the summer break. In the meantime I slathered some permatex silicone over the boots. My neighbor has an '03 as wel and the same thing is happening. Very poor design. "Sealed for life!" Why doesn't Ford use the old style boots that don't disintegrate and incorporate zerks?