Installation Manual
OTC COMPONENTS REQUIRED:
• Installing Adapter #204508A
• Installing Cup #38355A
• Installing Cup #38354
IMPORTANT: THOROUGHLY clean the surface
where the new ball joints will seat. DIRTY
MATING SURFACES WILL AFFECT BALL JOINT
ALIGNMENT AND TORQUING.
Using a ball joint press, press in the new ball
joints. It is IMPORTANT that the ball joints are
installed properly to prevent misalignment and
binding! Be sure to use the correct size adapter.
Refer to the following diagrams.
These ball joints press in and apply force on the
stud end of these applications. It is important
that the installation cup be placed on the outer
step of the ball joint housing. Pressing in the ball
joint with force against the inside lip may push
the lip and lower bearing into the stud, causing
binding and premature failure. Always press in
these ball joints using the outer step.
The upper ball joint must be installed before
the lower ball joint.
1. Clean the knuckle ball joint mating surfaces
throughly.
2. Apply a suitable lubricant to the ball joint
mating surface and assemble the ball joint
into the knuckle.
3. Assemble the ball joint press components
as shown in Fig 6. Check the alignment of all
components. Tighten the forcing screw until
the ball joint is firmly seated.
4. Install the snap ring on the upper ball joint.
5. Repeat Steps 1-3 to install the lower ball joint.
Install the snap ring.
6. Install the knuckle assembly to the vehicle
according to the vehicle service manual
procedures.
Tighten the UPPER ball joint nut to 94 Nm
(69 ft. lbs.) DO NOT USE AN IMPACT WRENCH.
An impact wrench can spin the stud at high speed
and cause premature failure. (FIG 8)
If necessary, tighten the nut until the cotter pin
can be installed. Install the cotter pin.
Tighten the LOWER ball joint nut to 204 Nm
(150 ft. lbs.). DO NOT USE AN IMPACT
WRENCH. An impact wrench can spin the stud at
high speed and cause premature failure. (FIG 7)
NOTE: Do not loosen the nut to install the cotter
pin. Always tighten to install the cotter pin.
Connect the tie-rod end to the wheel knuckle and
install the nut.
Tighten to 115 Nm (85 ft. lbs.) DO NOT USE
AN IMPACT WRENCH. An impact wrench can
spin the stud at high speed and cause premature
failure. If necessary, tighten the nut until the
cotter pin can be installed.
Complete the repair per the vehicle service
manual. Also, a wheel alignment should be
performed anytime ball joints are replaced.
Other factors to consider:
Inspect the steering damper if equipped. Binding
from internal rust can cause stiff steering and
poor steering wheel return-to-center.
It is important that the steering gear box is
properly adjusted. A steering gear box that is
worn or out of adjustment can cause steering
looseness, wandering, poor return-to-center,
and/or tight and stiff turning.
Install the camber adjuster sleeve (if equipped).
Position the wheel knuckle onto the axle
and install the nut onto the upper ball joint.
Do not tighten the nut at this time.
Apply threadlock and sealer to the threads of the
lower ball joint and install the nut onto the lower
ball joint. Do not tighten the nut at this time.
It is important that the following torque
procedures be followed:
Tighten the LOWER ball joint nut to 59 Nm (44
ft. lbs.) DO NOT USE AN IMPACT WRENCH. An
impact wrench can spin the stud at high speed
and cause premature failure. (FIG 7)
Installation Procedures Installation
Procedure
(con’t)
Installation
Procedure
(con’t)
7.
8.
INCORRECT
Installing Cup must
sit on outer step
Incorrect fit, not against outer step
INSTALLATION
Installing Cup
OTC #38354
Installing
Adapter
OTC #204508A
Upper Ball Joint
Installing Cup
OTC #38355A
Installing
Adapter
OTC #204508A
Lower Ball Joint
Installing Cup
OTC #38354
Installing
Adapter
OTC #204508A
Upper Ball Joint
Installing Cup
OTC #38355A
Installing
Adapter
OTC #204508A
Lower Ball Joint
6.
LOWER BALL JOINT - CORRECT
Installing Cup
OTC #38354
Correct fit, against outer step
K8607T
Outer step
UPPER BALL JOINT - CORRECT
Installing Cup
OTC #38355A
K80026
Correct fit, against outer step
Outer step
Ford Super Duty / Dodge Ram 2550/3500 Trucks with Straight Axles
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Continued from previous page
Ball Joint Replacement / Memory Steer Issues
Ford Super Duty / Dodge Ram 2550 / 3500 Trucks with Straight Axles
DY K12 -101
tech line:
1-800-325-8886
moogproblemsolver.com
www.FMe-cat.com
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