2006 XLT Front Lower Control Arms

[Scorpion8]

Thanks for this, I'm about to do the same repair. I was going to remove the entire knuckle, but what you did saves disconnecting the upper ball joint. Popping the axle out is not difficult at all. If you have an air hammer, use it on the end of the axle to vibrate it out of the hub. (I got this trick from Ford Makuloko.)

Good luck. All my axle shafts have been free inside the spline gear, just need a dead-blow or rubber mallet to persuade them a bit. Don't bung up the axle shaft threads.

 

[Larryjb]

Well, all worked out fine for the driver's side. Unfortunately, I could not get the passenger side LCA out, even with the axle free. I decided to go and just remove the knuckle at this point. The tie rod end came off fine (OEM 25112 works great on Ford ball joints), and the upper ball joint separated easily too. Unfortunately, the nut on the end of the ball joint shaft is frozen on the last few threads. Even though I soaked it with penetrating fluid before removing it, and wire brushed the threads, it got stuck. Yes, I tried using a 10 mm wrench on the end of the shaft while turning the nut, but the shoulders of the shaft just rounded. I tried vice grips, and it will won't budge. I tried turning it the other way (back on), and still no luck. I think I'm going to have to do do upper control arms as well. While I'm at it, I may as well do tie rod ends too. Unfortunately, I was hoping to have the vehicle on the road tomorrow.

 

[94Eddie]

Have you tried applying some heat?

 

[Larryjb]

Have you tried applying some heat?

Yup. But I only have propane which is not a lot of heat for this purpose.

 

[Blackhawkxx]

A small air angle grinder and slice the nut almost through or a nut splitter.

 

[Bazz270]

Agree

Nut splitter will do the job (use impact gun)

 

[Larryjb]

Agree

Nut splitter will do the job (use impact gun)

Thanks, looks like it's time to buy yet another tool! yeah.

 

[Larryjb]

Got the nut slitter. Unfortunately, this is a flange nut and it is pretty much impossible to cut the flange part. I got the nut cut through on two sides, but the flange is still holding it, and I cannot yet get the nut to turn free from the ball joint. I might try to position the nut so that the cutter can cut through the flange as well, but I foresee that as being rather difficult to achieve. We'll see.

With the damage to the threads on the ball joint itself, I pretty much need new upper control arms for sure now.

 

[Bazz270]

Not a problem at all

Ford sell motorcraft replacement balljoints for the LCA's

 

[Larryjb]

Not a problem at all

Ford sell motorcraft replacement balljoints for the LCA's

Just to clarify, the issue is with the UCA.

 

[Bazz270]

Well the upper balljoint available from the aftermarker manufacturers like Moog or Acdelco

 

[Larryjb]

Update:
I got the nut off from the upper ball joint. The trick was a lot easier than using a nut splitter. I used the ball joint separator to squeeze the knuckle back into the upper control arm which held the ball joint still. I then had room to use my impact to zip the nut right off. It came of within seconds.

I've ordered two new upper control arms complete with ball joints. This makes the job easier and quicker, and puts all new parts in.

 

[Scorpion8]

Yup. But I only have propane which is not a lot of heat for this purpose.

Try an air or electric impact to shock it and go on/off/on/off rapidly to urge it past those threads. Work it in the tightening direction a few threads, then back to loosening and back and forth., rapidly. Have you been successful?

 

[Larryjb]

Try an air or electric impact to shock it and go on/off/on/off rapidly to urge it past those threads. Work it in the tightening direction a few threads, then back to loosening and back and forth., rapidly. Have you been successful?

You will see my solution in Post #32 above.

The problem I had was the ball joint itself was spinning with the nut, so an impact alone was not helplful. (I have an electric impact.) Using the OEM tool to clamp the knuckle back into the ball joint kept the ball joint from spinning. The electric impact then got the nut off in about 3 seconds.

New UCAs have arrived and I will be installing them shortly.