Chrysler Full-Size Trucks 1989-1996 Repair Guide

Upper Ball Joint

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INSPECTION



To inspect the ball joints, unload the suspension and support the vehicle safely. Upper ball joints on 2WD vehicles and any ball joint on 4WD vehicles should be replaced if any play exists at all.

REMOVAL & INSTALLATION



Except Dakota
2WD MODELS
  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Position a support at the outer end of the lower control arm and lower the vehicle so that the support compresses the coil spring.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the cotter pin and the stud nut.
  8.  
  9. Release the upper ball joint taper using ball stud loosening tool C-3564-A, or equivalent.
  10.  
  11. Unthread the ball joint from the control arm with tool C-3561, or equivalent.
  12.  
  13. The installation is the reversal of the removal procedure. Tighten the ball joint itself to 125 ft. lbs. (169 Nm). Tighten the upper ball stud nut to 135 ft. lbs (183 Nm).
  14.  

4WD MODELS
  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Remove the front axle shaft.
  4.  
  5. Disconnect the tie rod end from the steering knuckle. On the left side, disconnect the drag link ball stud from the steering knuckle.
  6.  
  7. On the left side, remove the nuts and washers from the steering knuckle arm and remove the arm and spring, if equipped, from the knuckle.
  8.  
  9. If equipped with a Model 44 front axle, remove the ball joint nuts and discard the lower nut. Use a brass drift and hammer to separate the steering knuckle from the axle tube yoke. Use tool C-4169 to remove the sleeve from the upper yoke arm.
  10.  
  11. Remove the snapring from the ball joint. Install the knuckle in a vise and use tools D-150-1, D-150-3 and C-4212-L to remove the ball joint from the knuckle.
  12.  
  13. If equipped with a Model 60 front axle, remove the bolts from the knuckle lower cap. Dislodge the cap from the steering knuckle and axle tube yoke. Remove the steering knuckle. Use tool D-192 to remove the upper socket pin from the axle tube upper arm bore. Remove the seal.
  14.  

To install:
  1. If equipped with a Model 44 front axle, use tools C-4212-L and C-4288 to force the upper ball joint into the steering knuckle. Install the snapring and install a new rubber boot. Thread the replacement sleeve into the upper yoke bore so that 2 threads are exposed at the top of the yoke. Position the knuckle on the axle tube yoke and install a new lower ball stud nut, then tighten to 80 ft. lbs. (108 Nm). Using the special socket, tighten the sleeve to 40 ft. lbs. (54 Nm). Install the upper ball stud nut and torque to 100 ft. lbs. (136 Nm) and install a new cotter pin.
  2.  
  3. If equipped with a Model 60 front axle, use tool D-192 to install the upper socket pin to the axle tube upper arm bore. Install a new seal. Tighten to 500-600 ft. lbs. (668-813 Nm). Position the knuckle over the socket pin. Fill the lower socket cavity with grease. Install the lower cap and tighten the bolts to 80 ft. lbs. (108 Nm).
  4.  
  5. On the left side, install the spring, if equipped and the steering knuckle arm to the steering knuckle.
  6.  
  7. Connect the tie rod to the end of the steering knuckle. On the left side, connect the drag link ball stud to the steering knuckle.
  8.  
  9. Install the front axle shaft and all related components.
  10.  

Dakota
2WD MODELS
  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Position a support at the outer end of the lower control arm and lower the vehicle so that the support compresses the coil spring.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the cotter pin and stud nut.
  8.  
  9. Release the upper ball joint taper using ball stud loosening tool C-3564-A, or equivalent.
  10.  
  11. Unthread the ball joint from the control arm with tool C-3561, or equivalent.
  12.  

To install:
  1. Tighten the ball joint itself to 125 ft. lbs. (169 Nm).
  2.  
  3. Tighten the upper ball stud nut to 135 ft. lbs (183 Nm) and install a new cotter pin.
  4.  
  5. The installation of the remaining components is the reverse of the removal procedure.
  6.  

4WD MODELS
  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Remove the CV driveshaft from the vehicle.
  4.  
  5. Turn the torsion bar adjustment nut counterclockwise to relieve all tension from the torsion bar.
  6.  
  7. Remove the cotter pin from the upper ball stud.
  8.  
  9. Release the upper ball joint taper using ball stud loosening tool C-3564-A, or equivalent. Remove the tool.
  10.  
  11. Remove the upper ball stud seal.
  12.  
  13. Force the ball joint from the arm using the ball stud removal and installation tool C-4212.
  14.  

To install:
  1. Install the new ball joint using the ball stud removal and installation tool C-4212.
  2.  
  3. Install the ball stud seal.
  4.  
  5. Insert the upper ball stud in the steering knuckle arm bore and install the nut. Tighten the nut to 105 ft. lbs. (142 Nm) and install a new cotter pin.
  6.  
  7. Turn the torsion bar adjustment nut clockwise to apply a load on the bar.
  8.  
  9. Install the CV driveshaft and all related parts.
  10.  
  11. Lower the vehicle.
  12.  
  13. Set the front suspension height. The difference between the distance from the surface that the tires are on to the lower control arm inner pivot and the distance that the tires are on to the outer end of the arm is 1-1 1 / 2 in. (25-38mm).
  14.  

 
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