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From: http://en.allexperts.com/q/Ford-780/Ball-Joint-Replacement.htm Ball Joint Replacement [Ford Van] Remove the brake disc. Remove the wheel speed sensor. For additional information, refer to Section 206-09.
Remove and discard the cotter pin and nut.
Disconnect the tie-rod end.
Remove and discard the cotter pin and the nut.
Remove the pinch bolt adjuster.
CAUTION: To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints.
Remove the front wheel spindle.
Strike the lower end of the front axle to loosen the ball joint.
Remove the front wheel spindle.
To install, reverse the removal procedure.
Check and, if necessary, align the front end.
Remove the wheel spindle assembly. For additional information, refer to Wheel Spindle - E150-E450 in this section.
Position the front wheel spindle in a vise, and remove the snap ring from the lower ball joint.
CAUTION: To avoid damage to the components, do not use heat to aid ball joint removal.
Using the special tool and suitable receiver cup, remove the lower ball joint from the front wheel spindle.
Using the special tool and suitable receiver cup, remove the upper ball joint.
Installation
CAUTION: To avoid damage to components, do not use heat to aid installation.
NOTE: Clean the wheel knuckle ball joint bores.
NOTE: The lower ball joint must be installed first.
Using the special tool with suitable receiver cups, install the lower ball joint.
Using the special tool with suitable receiver cups, install the upper ball joint.
Install the snap ring in the groove at the bottom of the ball joint.
Install the front wheel spindle.
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