REMOVAL & INSTALLATION
See Figures 1, 2 and 3
Ford Motor Company refers to the entire knuckle and spindle assembly as a spindle.
- Place the steering wheel and front tires in the centered (straight ahead) position.
Anytime the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.
- Raise the van and support it safely with jackstands placed under the frame lifting pads. A hydraulic floor jack should be placed under the control arm to raise and lower the arm during coil spring removal. Make sure the van is supported securely on the jackstands and only work on one side at a time. Never service both front suspension assemblies at the same time.
- Remove the front tire and wheel assemblies.
- Remove the caliper, rotor and dust shield from the spindle. For more information, refer to Brakes .
- Remove the cotter pin and nut retaining the tie rod end to the spindle's lower arm. Disconnect the tie rod end with a suitable Pitman arm puller such as tool T64P-3590-F or equivalent.
- Support the lower control arm with a hydraulic floor jack. Make sure the jack pad securely contacts the control arm. Remove the cotter pin, then loosen the nut retaining the spindle to the lower control arm ball joint. Disconnect the lower ball joint from the spindle using the same Pitman arm puller used earlier, then remove the tool and ball joint retaining nut.
- Slowly lower the jack under the control arm until the ball joint is disengaged from the spindle.
- Remove the bolt and nut retaining the spindle to the upper control arm ball joint, then remove the spindle from the van.
- Position the spindle upper arm on the upper ball joint. Install the nut and bolt and tighten to 27-37 ft. lbs. (37-50 Nm). Inspect the upper and lower ball joint boot seals for damage and replace if necessary.
- Position the spindle lower arm over the ball joint stud, then slowly raise the lower control arm with the hydraulic jack until the ball joint stud extends through the spindle arm and is seated in the spindle. Install the ball joint castle nut and tighten it to 80-120 ft. lbs. (108-163 Nm), then install a new cotter pin. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align.
- Connect the tie rod end to the spindle arm. Firmly seat the tie rod end stud into the tapered hole to prevent rotation while tightening the castellated nut. Tighten the tie rod nut to 52-74 ft. lbs. (70-100 Nm), then install a new cotter pin. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align.
- Install the dust shield, rotor and caliper as described in Brakes .
- Install the front wheels.
- Lower the vehicle.