I just replaced these on my 2006. Here are some tips to help you do the same:
Removal:
0. Get two floor jacks. 3 works even better
1. Jack up both sides of front at same time. Remove wheels and disconnect end link (sway bar to strut connector) at the top connection. (6mm Allen key and 17mm wrench I recall). This allows for easier installation of new control arms... trust me!!! EVEN IF YOU ARE CHANGING ONLY ONE CONTROL ARM, BOTH END LINKS MUST BE DETACHED AT THEIR TOPS.
2. Pull cotter pin and remove castellated nut from ball joint.
3. Use a large pickle fork to separate the ball joint from steering knuckle. (I have a few ball joint tools for cars but nothing big enough for this truck... a big unused pickle fork did the trick).
4. Unbolt the large front and rear bolts holding control arm to frame. Front uses a 22mm socket and rear is 19mm.
5. Press the control arm down and man-handle the ball joint towards the back of the truck so that it is outside of the cup in the bottom of the steering knuckle.
6, Swing the control arm's front out of the front recess where the bolt went and continue to rotate it backward from the truck.
7. The control arm should now be hanging only from the recess where the rear bolt was. Pull the control arm away from the truck.
8. Repeat for other control arm if replacing two.
Installation:
1. Clean the threads and apply Grease/Antiseize the 2 bolts and into their respective holes in the control arm as well as in the recesses in the frame where the control arm will fit. Also grease/antiseize the threads on the new ball joint as well as greasing the tapered part.
2. Insert the new control arm only in the back recess and install the shorter bolt. Wiggle the contol arm and install the bolt. Turn it in so that you can visually confirm from the top that it is threaded nearly all the way to the top! Do not tighten it. This point will now act as a pivot. IMPORTANT: Make sure the bolt is grabbing the threads, not just pinched in place. This is very important as it is nearly impossible to insert this bolt after this step.... I KNOW!! VISUALLY VERIFY
3. Swing the control arm's front end into its recess in the frame. The new ball joint will hang-up on the sagging steering knuckle. The trick here is to man-handle the control arm's ball joint so that its threaded shaft goes up into the cup in the underside of the knuckle. Pushing down on the control arm and twisting the ball joint's threaded shaft favourably will help. A friend lifting the strut would not hurt either.
4. Push the control arm into the front recess. I had to use a hammer and long rod to drive it into position. By this time the ball joint's threaded shaft should have worked itself up into the steering knuckle and you should see the top of its threaded shaft peeking through.
5. Loosely install the castellated nut on the ball joint.
6. Install front bolt on control arm. A second floor jack under the control arm near the front bolt can help align it with the holes in the frames front recess. A small mirror can help a lot at aligning the bolt with the threaded welded nut.
7. Turn the two bolts and castellated nut so that they are just less than snug (~ 0.5mm from their final stop).
8. Repeat steps 1 to 7 for the other control arm if replacing two.
9. Use the second floor jack and place it under the new ball joint area.
10. Jack up the 2nd floor jack so that all of the load on that side of the truck is on the 2nd floor jack. (i.e. It should visually have lifted the the truck not just compressed the front strut).
11, Torque the 2 bolts and castellated nut (rear bolt 84 ft-lbs; front bolt 119 ft-lbs; castellated nut 69ft-lbs)
12. Install cotter pin in castellated nut.
13. If replacing two control arms, make sure you have completed all of the steps above for both sides before proceeding to step 14.
14. Install top end link on both sides of truck with the suspension hanging (clean threads, apply grease or anti-seize then torque to 58 ft-lbs)
15. Install wheel on this side and lower it to ground.
16. [If only one end link is connected and only one wheel is on the ground, there will be a large force on the sway bar making the end link difficult to install. In this case, use a floor jack under the control arm to raise it so that the end link can mate against its hole in the strut.
17. Install top end link (clean threads, apply grease or anti-seize then torque to 58 ft-lbs)
18. Install wheel on this side and lower it to ground.
19. Torque lug nuts.
Done!
Removal:
0. Get two floor jacks. 3 works even better
1. Jack up both sides of front at same time. Remove wheels and disconnect end link (sway bar to strut connector) at the top connection. (6mm Allen key and 17mm wrench I recall). This allows for easier installation of new control arms... trust me!!! EVEN IF YOU ARE CHANGING ONLY ONE CONTROL ARM, BOTH END LINKS MUST BE DETACHED AT THEIR TOPS.
2. Pull cotter pin and remove castellated nut from ball joint.
3. Use a large pickle fork to separate the ball joint from steering knuckle. (I have a few ball joint tools for cars but nothing big enough for this truck... a big unused pickle fork did the trick).
4. Unbolt the large front and rear bolts holding control arm to frame. Front uses a 22mm socket and rear is 19mm.
5. Press the control arm down and man-handle the ball joint towards the back of the truck so that it is outside of the cup in the bottom of the steering knuckle.
6, Swing the control arm's front out of the front recess where the bolt went and continue to rotate it backward from the truck.
7. The control arm should now be hanging only from the recess where the rear bolt was. Pull the control arm away from the truck.
8. Repeat for other control arm if replacing two.
Installation:
1. Clean the threads and apply Grease/Antiseize the 2 bolts and into their respective holes in the control arm as well as in the recesses in the frame where the control arm will fit. Also grease/antiseize the threads on the new ball joint as well as greasing the tapered part.
2. Insert the new control arm only in the back recess and install the shorter bolt. Wiggle the contol arm and install the bolt. Turn it in so that you can visually confirm from the top that it is threaded nearly all the way to the top! Do not tighten it. This point will now act as a pivot. IMPORTANT: Make sure the bolt is grabbing the threads, not just pinched in place. This is very important as it is nearly impossible to insert this bolt after this step.... I KNOW!! VISUALLY VERIFY
3. Swing the control arm's front end into its recess in the frame. The new ball joint will hang-up on the sagging steering knuckle. The trick here is to man-handle the control arm's ball joint so that its threaded shaft goes up into the cup in the underside of the knuckle. Pushing down on the control arm and twisting the ball joint's threaded shaft favourably will help. A friend lifting the strut would not hurt either.
4. Push the control arm into the front recess. I had to use a hammer and long rod to drive it into position. By this time the ball joint's threaded shaft should have worked itself up into the steering knuckle and you should see the top of its threaded shaft peeking through.
5. Loosely install the castellated nut on the ball joint.
6. Install front bolt on control arm. A second floor jack under the control arm near the front bolt can help align it with the holes in the frames front recess. A small mirror can help a lot at aligning the bolt with the threaded welded nut.
7. Turn the two bolts and castellated nut so that they are just less than snug (~ 0.5mm from their final stop).
8. Repeat steps 1 to 7 for the other control arm if replacing two.
9. Use the second floor jack and place it under the new ball joint area.
10. Jack up the 2nd floor jack so that all of the load on that side of the truck is on the 2nd floor jack. (i.e. It should visually have lifted the the truck not just compressed the front strut).
11, Torque the 2 bolts and castellated nut (rear bolt 84 ft-lbs; front bolt 119 ft-lbs; castellated nut 69ft-lbs)
12. Install cotter pin in castellated nut.
13. If replacing two control arms, make sure you have completed all of the steps above for both sides before proceeding to step 14.
14. Install top end link on both sides of truck with the suspension hanging (clean threads, apply grease or anti-seize then torque to 58 ft-lbs)
15. Install wheel on this side and lower it to ground.
16. [If only one end link is connected and only one wheel is on the ground, there will be a large force on the sway bar making the end link difficult to install. In this case, use a floor jack under the control arm to raise it so that the end link can mate against its hole in the strut.
17. Install top end link (clean threads, apply grease or anti-seize then torque to 58 ft-lbs)
18. Install wheel on this side and lower it to ground.
19. Torque lug nuts.
Done!