Ford F150 Pickup. Instruction — part 1789

Fig. 1: Exploded View Of Front Suspension
Courtesy of FORD MOTOR CO.

ADJUSTMENTS

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 2WD Coil Spring - F150 Pickup

BALL JOINT CHECKING

Raise and support front of vehicle under lower control arm. Have assistant grasp tire at upper and lower edge.
Move tire in and out in a rocking motion while observing the upper and lower ball joints. If movement exceeds
0.06" (1.5 mm), replace ball joint(s).

WHEEL ALIGNMENT

WHEEL BEARING

Raise the vehicle until the tire is off the floor. Individually grasp each front tire at the top and bottom, moving
the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. Make sure the
wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel
assembly. If the tire and wheel hub is loose on the wheel spindle or does not rotate freely, adjust the front wheel
bearings. To adjust, tighten wheel bearing adjusting nut to 30 ft. lbs. (41 N.m) while rotating wheel clockwise.
Stop rotation, and back off adjusting nut 2 turns to release all preload. Retighten wheel bearing adjusting nut to
17-24 ft. lbs. (23-33 N.m) while rotating wheel counterclockwise. Stop rotation, and back off adjusting nut.
Retighten nut to 17 INCH lbs. (2 N.m). Install NEW cotter pin, coat grease cap lightly with grease, and install
cap.

REMOVAL & INSTALLATION

BALL JOINT (LOWER)

Removal

1. With the vehicle in neutral, raise and support vehicle. Remove the wheel and tire assembly. Remove the

caliper support bracket bolts, then position the caliper support bracket and brake caliper aside. DO NOT
allow caliper to hang suspended from the brake hose.

2. Disconnect the front Anti-Lock Brake System wire assembly (if equipped). Disconnect the ABS electrical

connector. Unclip the ABS harness routing clips.

3. Remove and discard the tie-rod end cotter pin. Remove and discard the castellated nut. Using the Pitman

Arm Puller (T64P-3590-F), separate the tie-rod end from the front spindle. Using a suitable jack, support
the front suspension lower arm.

4. Remove and discard the lower ball joint cotter pin. Remove the lower ball joint castellated nut. Using the

pitman arm puller, separate the front spindle from the suspension lower arm. Then, loosely reinstall the
castellated nut.

5. Remove and discard the upper ball joint cotter pin. Remove the upper ball joint castellated nut. Using the

NOTE:

See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

WARNING:

Always remove any corrosion, dirt or foreign material from wheel
mounting surfaces. If wheel are installed without proper metal-to-metal
contact at wheel mounting surfaces, lug nuts can loosen while vehicle is
in motion. Recheck lug nut torque 500 miles after wheel installation.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 2WD Coil Spring - F150 Pickup

pitman arm puller, separate the front spindle from the front suspension upper arm. See Fig. 5 . Remove
the hand-tightened lower ball joint castellated nut, then remove the spindle.

6. Remove the snap ring from the ball joint. Discard the snap ring. Using the C-Frame And Screw

Installer/Remover (T74P-4635-C), remove the lower ball joint. See Fig. 2 . Clean and inspect the control
arm ball joint bore for damage.

Fig. 2: Removing Lower Ball Joint
Courtesy of FORD MOTOR CO.

Installation

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 2WD Coil Spring - F150 Pickup

To install, reverse the removal procedure. Always install new castellated nuts and cotter pins. Tighten all nuts
and bolts to specifications. See TORQUE SPECIFICATIONS .

COIL SPRING

Removal

1. Raise vehicle, and position safety stands under frame. Remove wheels.

2. Remove shock absorber. See SHOCK ABSORBER . Remove brake hose bracket from lower control

arm. Remove stabilizer bar link nut.

3. Using Coil Spring Compressor (D78P-5310-A), compress spring sufficiently to remove tension from

lower control arm. Remove and discard lower ball joint cotter pin. Remove lower ball joint nut. Using
Pitman Arm Puller (T64P-3590-F), separate lower ball joint from spindle. Position spindle aside. Remove
coil spring.

Installation

1. To install, reverse removal procedure. Install NEW cotter pins. Ensure end of spring is positioned

properly between 2 holes in lower control arm. See Fig. 3 . Tighten all nuts and bolts to specification. See
TORQUE SPECIFICATIONS .

2. Before driving vehicle, pump brake pedal several times to restore normal pedal position. Check wheel

alignment. See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

NOTE:

Make sure the NEW ball joint snap ring is fully seated.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 2WD Coil Spring - F150 Pickup