Balljoint Installation Instructions Ford
Contents
1. DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING DYNATRAC PRODUCTS 1999 2008 4X4 Ford Super Duty amp Dodge 1994 1999 2500 3500 Heavy Duty Ball Joint Kit ProSteer Ball Joint Installation V2 0 A WARNING This product is designed for use in specified axles and should not be used for custom applications Any non approved application will risk your safety and the safety of others around you Any non approved use will void the warranty of the product A WARNING Improper use or installation of this product can cause major failures that could lead to injury or death FT tii There are knock off axle products that are not made to Dana specifications Dtynatrac will not be accountable for the tolerances of non Dana or Dynatrac products on the market AWARE OEM ball joint camber bushings range from 0 0 Deg to 2 0 Deg This product is not designed for use with camber bushings over 75 Deg INFORMATION Dynatrac ball joints are sold in a fully assembled condition ready to install in your vehicle Install the ball joints as if they are standard OEM replacement parts Refer to your vehicle or axle service manual or contact a competent auto repair or alignment shop to properly install the ball joints on your vehicle Press tools are required when installing ball joints and it is recommended that you use an experienced shop There are ball joint press tool kits available online or at auto stores For the do it yourself guy Dynatrac re2. NG e Torque lower ball joint to 35ft Ibs e Torque upper ball joint to 71 ft Ibs then turn the nut until the next slot lines up with the cotter pin e Insert the cotter pin into the hole and bend the tab over e Re torque lower ball joint to 140 160 ft Ibs Figure 10 Pry Bar to Leverage Camber Bushing Figure 11 Tightening the Upper Ball Joint Reassembly of Wheel end 12 At this point the knuckle should be properly bolted to the end forging Refer to the service manual and reassemble the wheel end After everything has been installed check the wheel alignment Make sure the axle is filled with gear oil if the differential was drained prior to disassembly AN WARNING Failure to properly refill the axle with Gear Oil can cause serious gear and bearing failure which could result in serious injury or death A WARNING Failure to check bolt and lug nut torque can cause serious accident component failure serious injury or death Bill of Materials DA60 2X3050 A Description Qty Dynatrac P N Upper Ball Joint 2 DA60 1X3049 B Lower Ball Joint 2 DA60 1X3050 B Lower Body Snap ring 2 DA60 3050 K 3 4 Castle Nut 2 DA60 3049 F Cotter Pin 2 DA60 3049 K Lock Nut 2 DA60 3050 F DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 7 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING DAGO 1X3050 B FORD INSTAL BUSHING KIT DAGO 2X3050 A FORD PS BALL JOINT KIT BUY FROM DYNATRAC OR MAKE A
3. SIMILAR SET DAGO 3050 0 COTTER PIN X 2 DAGO 3050 N DAGO 3049 K l _ 2 000 G2 500 h 3 4 CASTLE NUT X 2 DAGO 3049 F i h 1 760 2 000 UPPER BALL JOINT DA60 1X3049 B X 2 7 8 LOCK NUT X 2 DA6O 3050 F LOWER BALL JOINT SNAP RING X 2 DA6O0 1X3050 B X 2 DA6GO 3050 K BUSHING WIDTH 5 X 3 PCS Figure 12 Ball Joint BOM Figure 13 Additional Bushing Install Kit AXLE TERMINOLOGY UPPER BALL JOINT STUD CAMBER BUSHING UPPER BALL JOINT KNUCKLE ENO FORGING LOWER BALL JOINT STUD LOWER BALL JOINT Figure 14 Axle Tech DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 8
4. commends using Miller Press Kit 8975 in conjunction with kit CR9 2 1X3050 C supplied by Dynatrac Fig 13 Other ball joint installation kits besides the listed Miller kit are available however Dynatrac has not tested them The Dynatrac installation kit may also be used with other off the shelf kits Note Dynatrac strongly recommends buying the Dynatrac ball joint installation kit sold separately Fig 13 The Dynatrac ball joint installation kit will prevent damage to the ball joints during installation Common Tools Which Will be Required e Ball Joint Press Kit or Shop Press Equipment Miller Kit 8975 o Miller Tool kit 8975 with the Dyantrac Kit sold Separately o C Clamp Miller C 4212 F o Press Tools Miller 8975 1 8975 2 8975 3 8975 4 8975 5 6289 3 e 1 5 16 Socket e 1 1 8 Socket e Calibrated Torque Wrench DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 1 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING Pry Bar Wire Brush 4 Quarts of Gear Oil Optional Installation Instructions A WARNING Only perform this installation if you are an experienced fully equipped mechanic A WARNING Always wear proper safety equipment including safety glasses and gloves while working with tools Improper use of tools and equipment can cause injury or death Preparation and Inspection 1 As stated above only perform the installation if you are a fully equipped mechanic Us
5. epeat the procedure for the opposite knuckle DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 3 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING Figure 3 Removing the Upper Ball Joint Figure 4 Removing Lower Ball Joint Prepping the Ball Joint Bores 6 Once all of the ball joints have been removed use brake cleaner or another solvent to clean the bores in the knuckle and end forging It is extremely important to clean any rust or sediment build up off of the end forging faces where the ball joints will seat This can be done using a wire wheel wire brush Scotch Bride or 100 grit sand paper Fig 5 Cleaning of the end forging bores is extremely important to make sure the ball joints seat correctly Installing Dynatrac Ball Joints A WARNING Shop presses exert tremendous force and can easily damage components if caution is not exercised A WARNING Pressing on the seal when installing the lower ball joint will damage the seal Exercise great caution when installing the ball joints to reduce the risk of damage Note Dynatrac strongly recommends using the Miller tool kit in conjunction with the Dynatrac Ball Joint installation kit Preparation DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 4 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING 7 After the knuckles and end forgings have been cleaned place Anti Sieze on al
6. ing the attached bill of materials verify the kit is complete Figure 12 Contact Dynatrac if the kit does not include all the listed parts 714 596 4461 You may need anywhere between 4 to 10 hours depending on your experience so allow plenty of time If you are performing the installation at home Dynatrac strongly recommends using the miller ball joint kit with the Dynatrac kit Dynatrac also recommends using kit number DA60 1X3050 C with all other installation kits Fig 13 Removing the Knuckle 2 Because there are several axle designs it is recommended a service manual specific to the vehicle is used Publications are available online that offer detailed instructions for replacing ball joints Remove the wheel hub assembly brakes tie rod and all other miscellaneous hardware as outlined in the service manual At this point the bare knuckle is exposed and ready for disassembly Figure 1 Once the knuckle is exposed remove the castle nut from the upper ball joints Loosen the lower ball joint nut until 3 5 threads are still on the nut this will prevent the knuckle from falling off Since the ball joints have a tapered stud they will be firmly seated in the end forging To remove the ball joint stud from the end forging use a 5Lb metal hammer to hit the bottom of the end forging Several hard well directed blows should cause the ball joint stud to fall out of the end forging At this point you will have the knuckle with the ball joints s
7. l the ball joint bodies Figure 4 There is a significant amount of force required to install the ball joints Anti Seize will help prevent galling and damage to the axle components when installed Fig 6 Figure 5 Cleaning the Knuckle Figure 6 Placing Anti Seize on Ball Joints A WARNING Do not press on the seal when installing the ball joints or it will damage the parts Fig 7 DO NOT PRESS ON SEAL SURF ACE OR STUD WILL DAMAGE COMPONENTS USE RIM WHEN PRESSING BALL JOINTS Figure 7 Proper Press Location Installation of Lower Ball Joint 8 After all of the ball joint bores and bodies have been cleaned and prepped with Anti Sieze they will be ready for installation Install the lower ball joint first with either a shop press or a C Clamp press kit If you are using a C Clamp kit use tools C4242 F 8975 1 DA60 3050 N DA60 3050 P and 7975 2 Using that combination of tools press the lower ball joint into the knuckle Fig 8 Repeat the procedure for the opposite side After the ball joints are installed insert the snap ring around the body of the lower ball joint Installation of Upper Ball Joint DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 5 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING 9 Once the lower ball joints are installed the upper ball joints may be pressed in Using the miller press kit use tools C4212 F DA60 3049 0 8975 1 and 8975 3 to in
8. stall the upper ball joint Fig 9 Make sure the ball joint is fully seated on the knuckle pei 4 e DAG0 304980 DTC LOWER BALL JOINT 8975 3 Installation of Knuckle 10 Now the knuckle is ready for installation A 1 5 16 socket and a 1 1 8 socket are required to tighten the ball joint nuts Be sure to clean the tapered shafts with brake cleaner or acetone this will help prevent the shaft from spinning during assembly Place the knuckle into the end forging and lightly screw on the ball joint nuts preventing the knuckle from sliding out 11 Place a screw driver or pry bar under the camber bushing on the upper ball joint Figure 10 Tighten the upper ball joint with the pry bar underneath the bushing This will seat the lower ball joint into the end forging taper and allow you to tighten the lower ball joint to 35 ft Ibs of torque Once the lower ball joint has been tightened to the first torque specification remove the pry bar from the upper ball joint Tighten the upper ball joint with an open ended wrench There is a flat milled on the upper ball joint stud so a second wrench may hold the shaft preventing it from spinning Figure 11 After the castle nut is drawn into the bushing the upper ball joint may be torqued to the specified value of 71 ft Ibs Torque Procedure DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 6 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDI
9. till pressed inside of them Figure 2 DYNATRAC PRODUCTS CO PATENT PENDING FORD BALL JOINT INSTALLATION INSTRUCTIONS Page 2 DYNATRAC PROSTEER INSTALATION INSTRUCTIONS PATENT PENDING Figure 1 Knuckle with wheel end removed Figure 2 Removing the knuckle Pressing Out Ball Joints Note There are two primary ways of removing the ball joints form the knuckle If you are an experienced shop you may use press equipment to remove the ball joints from the knuckle If you do not have press equipment Dynatrac recommends using the C Clamp press kit referenced in the tool list In Both cases Dynatrac recommends buying the additional tool kit or making a similar set of bushings to prevent damage to the seals Removing the Upper Ball Joint 4 Atthis point the old ball joints may be pressed out by using shop press equipment or a C Clamp press kit Place the knuckle in a vise or clamp the knuckle to a sturdy table Remove the upper ball joint first using Miller tool kit Tools C 4212 F 8975 2 8975 4 Use tool 8975 2 to receive the ball joint and tool 8975 4 to push the ball joint out Fig 3 Repeat the procedure for the opposite knuckle Removing the Lower Ball Joint 5 After the upper ball joints have been pressed out the lower ball joints may be removed Remove the lower ball joint first using Miller tool kit Tools C 4212 F 8975 2 8975 4 Use tool 8975 2 to receive the ball joint and tool 8975 4 to push the ball joint out Fig 4 R
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