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does anyone have a pictured-assisted description of how to remove a lower ball joint (94 F150 2wd), and replace with a new one ? I'd like to keep disassembly of any other components to a minimum. (ie. do I have to remove the tie rod etc.?)
let's take it from, I've got the front right wheel off, and can even take the brake rotor off - I'm looking at a well rusted, cotter-pinned, castle nut.. I'm starting from there..
Use a tie rod separator fork and you can reuse the tie rod if it's good. If you can't work the cotter key free and most of the time ya can't. Just cut/break the cotter key off flush with the nut on both sides and then unscrew the nut over it. The heat created by removing the nut usually allows the cotter key to be punched out right after removing the nut, have a hammer and punch ready. Then use the fork to free the tie rod end being careful of the rubber boot.
If you don't get the key out double nut it when you put it back together.
Tie the caliper up, do not let it hang by the line.
Replace the upper and lower while you have that side apart, trying to do one without damaging the other is a waste of time. Both will be under a 100 bucks, make sure you get greaseable replacement parts.
You can buy or rent a ball joint press all though I've never used one.
IF you've never done it you may want to rent one, it would be much easier for you to get the new ones in without damaging them in the process.