94 grand voyager how to remove lower ball joint. will i damage seal? I am replacing axle but not ball joint. I will use ball joint removal tool

remove lower ball joint and remove axle nut in the center of spindle. then move the spindle out of the way separating the axle from the spindle.

Lower Control Arm

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The lower control arm is a two-piece welded unit with a riveted ball joint. A conventional rubber bushing is used for the rear lower control arm pivot. The front lower control arm bushing is mounted vertically.

REMOVAL AND INSTALLATION

Some special tools are required to perform this operation including, a front hub spindle removal tool and a suitable ball joint separator tool.

WARNING Do not hammer or pry ball joint from knuckle. Failure to use recommended tools may cause damage to the ball joint and seal.
See Figure 1

Fig. Fig. 1: Exploded view of the control arm-to-frame mounting

1. Raise the vehicle and suitably support by the frame allowing the control arms to hang free.
2. Remove the wheel and tire assembly.
3. Remove the steering gear outer tie rod from the steering knuckle.
4. Remove the stabilizer shaft link from the control arm.
5. Remove the front drive axle shaft nut and washer.
6. Use a suitable front hub spindle removal tool to Push the axle splines back out of the front wheel drive shaft bearing.
7. Remove the drive axle from the transaxle.

Drive axle joint seal protectors should be used anytime service is performed on or near the drive axles. Failure to observe this could result in joint or seal failure.

1. Place a modified inner drive joint seal protector on the drive axle joints.
2. If equipped, remove the ABS wheel speed sensor jumper harness.
3. Remove and discard the cotter pin, then loosen the nut from the ball stud.
4. Remove the pinch bolt and the control arm mounting bolts, then remove the control arm from the vehicle.

Wheel Spindle, F-150, F-250, F-350
Removal

1. Raise the front of the vehicle and install safety stands.
   

1. Remove the wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove the disc brake caliper (2B120) from the rotor and wire it out of the way. Refer to Section 06-03 .
   

1. Remove the dust cap, cotter pin, nut retainer, nut, washer and front wheel bearing (1216).
   

1. Remove the rotor from the front wheel spindle (3105).
   
   
   
   
   
   Item Part Number Description 1 606085 Clamp Bolt 2 3B404 Camber Adjuster 3 800895 Nut 4 800937 Nut 5 3049 Front Suspension Upper Ball Joint 6 3050 Front Suspension Lower Arm Ball Joint 7 3105 Front Wheel Spindle 8 642569 Cotter Pin 9 3304 Steering Sector Shaft Arm Drag Link 10 383489 Nut 11 3001 Front Axle Assembly 12 388727 Bolt A - Tighten to 77-103 Nm
   (57-75 Lb-Ft) B - Tighten to 68-92 Nm
   (50-67 Lb-Ft) C - Tighten to 113-153 Nm (83-112 Lb-Ft) D - Tighten to 340-460 Nm (250-339 Lb-Ft)

1. Remove bearing cone and roller (1201) and wheel hub grease seal (1190). Discard the seal.
   

1. Remove front disc brake rotor shield (2K004). Refer to Section 06-03 .
   

1. Disconnect the steering linkage from the integral front wheel spindle and spindle arm by removing the cotter pin and nut and then removing the front wheel spindle tie rod from the spindle arm with Tie Rod End Remover TOOL-3290-D or equivalent.
   

1. Remove the cotter pin and castellated nut from the lower ball joint stud.
   

1. Remove the nut from the axle clamp bolt and remove the bolt from the axle.
   

1. Remove the camber adjuster from the upper ball joint stud and axle beam. If required, use Ball Joint Removing Tool D81T-3010-B or equivalent to remove adjuster.
   

1. CAUTION: Do not use a pickle fork to separate the ball joint from the axle as this will damage the seal and the ball joint socket.
   Strike the inside area of the axle as shown to pop lower ball joints loose from the axle beam.
   

1. Remove the front wheel spindle and ball joint from the axle.
   
   

Ball Joint, F-150, F-250, F-350 SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number U-Joint Tool T74P-4635-C Ball Joint Remover T94T-3010-AH
Removal

1. Remove the front wheel spindle (3105) and ball joint assembly from the axle. Refer to Wheel Spindle, F-150, F-250, F-350 in the Removal and Installation portion of this section.
   

1. NOTE: Lower ball joint must be removed first.
   
   Install the front wheel spindle in a vise and remove the snap ring from the lower ball joint.
   

1. Remove the lower ball joint from the front wheel spindle using U-Joint Tool T74P-4635-C and Receiver Cup D81T-3010-A5 or equivalent for F-150. Use Ball Joint Remover T94T-3010-AH for F-250 and F-350.
   

1. Turn the forcing screw clockwise until the ball joint is removed from the front wheel spindle.
   
2. CAUTION: Do not heat the ball joint or the front wheel spindle to aid in removal.
   Assemble U-joint tool and cup on the upper ball joint, and turn forcing screw clockwise until ball joint is removed from the front wheel spindle.
   
   
   Installation
   
   1. CAUTION: Do not heat the ball joint or axle to aid in installation.
      NOTE: Upper ball joint must be installed into the front wheel spindle first.
      
      NOTE: Individual ball joint tools are included in Ball Joint Adapter Set D81T-3010-A or equivalent.
      
      To install the upper ball joint, assemble C-frame assembly, Ball Joint Receiver Cup D81T-3010-A5 and Installation Cup D81T-3010-A1 and D81T-3010-A3 or equivalents inside cup D81T-3010-A4 or equivalent in position on the front wheel spindle.
      
   1. Turn forcing screw clockwise until ball joint is seated.
      
      
      
      
   

remove passenger side wheel remove center nut on axle shaft i believe a 33 mm remove cotter pin on lower ball joint remove nut on lower ball joint with a ball joint seperating tool(pickle fork) seperate lower ball joint might need to tap axle shaft out of the wheel bearing pull the whole assembly aside where the axle goes into the transmission use a pry bar and pry out on the axle sometimes are stuck in pretty good then reverse the procedure to install be sure to torqe axle nut to specefications
good luck chris

To perform the following procedure, the lower control arm must be removed from the vehicle. Refer to Removal And Installation for that procedure.

1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly
2. Position receiving cup, Special Tool 6758 to support lower control arm when removing ball joint assembly. Install Remover, Special Tool 6919 on the top of the ball joint assembly.
3. Using the arbor press, press the ball joint assembly completely out of the lower control arm.

NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch in ball joint stud is in the direction shown. This will ease assembly of the ball joint to the steering when installing pinch bolt.

1. By hand, position ball joint into ball joint bore of lower control arm. Be sure ball joint is not cocked in the bore of the control arm, this will cause the ball joint to bind when being pressed into control arm.

 

1. Position control arm with installed ball joint, in an arbor press with Receiving Cup, Special Tool 6758 supporting the lower control arm. Then center Installer, Special Tool 6908-4 on the bottom of the ball joint
2. Carefully align all pieces. Then press the ball joint into the lower control arm until it is completely seated against surface of lower control arm. The ball joint is correctly installed when there is no gap between the ball joint and the lower control arm. Do not apply excessive force against the ball joint or the lower control arm.
3. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown.

CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.

1. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm.

CAUTION: A replacement ball joint is not pre-lubricated. Properly lubricate the replacement ball joint using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of the ball joint.

CAUTION: After the ball joint is properly greased, clip the end of the grease fleeing off below the hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in damage to the seal boot.

1. Reinstall lower control arm on vehicle.

1. Raise and safely support the vehicle.
2. Place jackstands under the frame.
3. Lower the car slightly so the weight rests on the jackstands and not the control arm.
4. Remove the front tire and wheel assembly.

Be careful to avoid over-extending the axle shaft joints. When either end of the shaft is disconnected, over-extension of the joint could result in separation of internal components and possible joint failure. Failure to observe this can result in interior joint or boot damage and possible joint failure.

1. If a silicone (gray) boot is used on the inboard axle joint, install boot seal protector J-33162 or equivalent. If a thermoplastic (black) boot is used, no protector is necessary.
2. Remove the cotter pin from the ball joint castellated nut. Discard the pin.
3. Remove the castellated nut and disconnect the ball joint from the steering knuckle using ball joint separator J-34505, J-29330, or equivalent.

Be sure to use on the recommended tool for separating the ball joint from the knuckle. Failure to use the proper tool may cause damage to the ball joint and seal.

1. Drill out the three rivets retaining the ball joint to the lower control arm. Use a 1 /8 in. (3mm) drill bit to make a pilot hole through the rivets. Finish drilling the head of the rivets with a 1 /2 in. (13mm) drill bit. Do NOT drill completely through the control arm.

Be careful not to damage the drive axle boot when drilling out the ball joint rivets.

1. Unfasten the nut attaching the link to the stabilizer shaft.
2. Remove the ball joint from the steering knuckle and control arm.

To install:

1. Position the ball joint in the control arm.
2. Install the three ball joint bolts and nuts as shown on the instruction sheet in the ball joint kit, then tighten the bolts to specifications.
3. Position the ball joint stud through the steering knuckle.
4. Fasten the ball joint-to-steering knuckle nut to 41-50 ft. lbs. (56-68 Nm).
5. Install a new cotter pin to the ball joint castellated nut.
6. If installed, remove the boot protector.
7. Fasten the nut attaching the stabilizer link to the stabilizer shaft. Tighten to 22 ft. lbs. (30 Nm), then slightly raise the vehicle and remove the jackstands from under the suspension.
8. Install the front tire and wheel assembly and hand-tighten the lug nuts.
9. Carefully lower the vehicle, then tighten the wheel lug nuts to 103 ft. lbs. (140 Nm).

Thanks for using FixYa - a 4 THUMBS rating is appreciated for answering your FREE question.

Not much to it,
remove wheel,remove axle nut,remove bolt and nut that pinch lower ball joint in place,it will either be an 18mm or a 21mm,pry lower control down to detach and separate ball joint,tap CV shaft in where you took the nut off,
hold out on rotor assembly while pushing CV shaft in ward,When you have the CV out of the bearing and rotor assembly,Tap inside CV joint out of transmission.

Removal & Installation NOTE This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 34874 Booster Seal Remover/Installer, J 41435 Ball Joint Installer, J 45105-1 Ball Joint Flaring Adapter and J 45105-2 Receiver.

1. On 4WD vehicles, remove the wheel center cap and drive axle nut.
   
2. Raise and support the vehicle.
   
3. Remove or disconnect the following:
   
   • Tire and wheel
     
   • Wheel hub and bearing, if necessary
     
   • Outer tie rod retaining nut
     
   • Out tie rod from the steering knuckle using a suitable puller
     
   • Brake hose bracket retaining bolts and bracket
     
   • Upper control arm-to-steering knuckle pinch bolt and nut
     
   • Upper control arm from the steering knuckle
     
   • Lower ball joint retaining nut
     
   • Steering knuckle from the lower control arm using a suitable ball joint removal tool
     
   • Steering knuckle from the vehicle
     
   • Lower ball joint flange with a chisel
     
4. Install tools J 9519-E and J 34874 to the lower ball joint, then use those tools to remove the lower ball joint from the lower control arm.
   

To install:

1. Install or connect the following:
   
   • Lower ball joint to the lower control arm, using tools J 9519-E, J 41435 and J 45105-2
     
2. Remove the tools from the lower control arm.
   
   • Tools J 9519-E and J 45105-1 to the lower ball joint
     
3. Flare the lower ball joint flange with J 9519-E and J 45105-1, then remove the tools from the lower ball joint.
   
   • Steering knuckle to the lower control arm
     
   • Lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm)
     
   • Upper control arm to the steering knuckle
     
   • Upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (41 Nm)
     
   • Brake hose bracket to the steering knuckle
     
   • Brake hose bracket retaining nuts and tighten to 7 ft. lbs. (10 Nm)
     
   • Outer tie rod to the steering knuckle
     
   • Outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm)
     
   • Wheel hub and bearing, if removed
     
   • Tire and wheel
     
4. Lower the vehicle
   
   • Drive axle nut, if 4WD, and tighten to 103 ft. lbs. (140 Nm)
     
   • Wheel center cap, if removed
     
5. Check the front wheel alignment.
   

separate the ball joint and the tie rod from wheel unit and swing it out far enough to slip axle out of wheel, pry it out of trans and replace

You don't need the special tools that they use in this procedure, you can use a hammer and a block of wood to get the axle out of the hub and you can use a pry bar to get the axle out of the transmisson.



Notice: Care must be exercised to prevent the constant-velocity joints from being over-extended. When either end of the drive axle is disconnected, over-extension of the joint could result in separation of internal components and possible joint failure. Drive axle joints and seals should be protected any time service is performed on or near the drive axles. Failure to observe this can result in interior joint or seal damage and possible joint failure.
Notice: Prior to removal of drive axle assembly, cover all sharp edges in the area of the drive axle with shop towels so that the seal is not damaged during removal.
Removal Procedure

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Place shop towels underneath the outer joint to protect from any sharp edges.




4. Insert a drift (1) into the caliper and the rotor to prevent the rotor from turning.
5. Remove the drive axle nut (2) and the washer.
6. Remove the lower ball join from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension. If you remove the right axle, turn the wheel to the left. If you remove the left axle, turn the wheel to the right.
7. Disconnect the wheel speed speed sensor harness. Refer to Wheel Speed Sensor Replacement in Antilock Brake System.
8. Disconnect the stabilizer link from the lower control arm. Refer to Stabilizer Shaft Link Replacement in Front Suspension.




9. Use the J 28733-B in order to disengage the axle from the hub and the bearing.
10. Separate the hub and the bearing assembly from the drive axle. Move the strut and the knuckle assembly rearward.




11. Remove the inner joint from the transaxle using J 33008 attached to J 29794 and J 2619-01 for the intermediate shaft, if equipped.

Installation Procedure Notice: Prior to installation of drive axle assembly, cover all sharp edges in the area of the drive axle with shop towels so that the seal is not damaged during installation.
Any time the front halfshaft is removed, the transmission (the halfshaft male and female shank) and the knuckle sealing surfaces should be inspected for debris or corrosion.
If debris or corrosion are present on the sealing surfaces, clean them with a 320 grit cloth or equivalent. Transmission fluid may be used to clean off any of the remaining debris. The surface should be wiped dry, and the halfshaft should be reinstalled free of any debris or corrosion buildup.

1. Install the drive axle (2) into the transaxle (1). Place a non-ferrous drift into the groove on the joint housing and then tap until the drift is seated. Be careful not to damage the axle seal or dislodge the seal garter spring when you install the axle.



Important: Verify that the drive axle is seated by grasping on the inner joint housing and pulling outboard.

2. Install the drive axle (1) into the hub and bearing assembly (2).
3. Install the stabilizer link. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
4. Connect the wheel speed sensor harness. Refer to Wheel Speed Sensor Replacement in Antilock Brake System.
5. Install the lower ball joint to the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.



Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the washer and the new drive axle nut (2).
Insert a drift (1) into the caliper and the rotor in order to prevent the rotor from turning.
Tighten
Tighten the drive axle nut to 200 N·m (144 lb ft).

7. Install the tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Lower the vehicle