DIY Ball Joint Installation Tool

[velorider]

I just installed ball joints on my S60 and built this tool to hammer them in. They went in super easy, the secret is to freeze them overnight, this shrinks them just enough to make installation 50% easier .

Parts:
2" PVC Schedule 40
2" PVC Cap
10x1.25 50mm Bolt

To insure the ball joints are aligned correctly, place the ball joints into the knuckle, use the 10x1.25 bolts to align the bolt joint with the thread holes in the knuckle. I left the plastic boot protection on when I place the PVC installation tool over the ball joint and hammered away. You have about 3-4 minutes while the ball joint is coldest.

Some Hints Replacing Ball Joint:
* I find it easiest to remove the knuckle, versus prying the control arm. I've done it with the ratchet strap method, so much harder. Specially if your control arms are new.
* With the knuckle removed, using a cheap Harbor Freight air hammer makes removing the old ball joint a breeze

[abscate]

In Calgary or Edmonton, just put the ball joints on the front porch, then push them in with your fingers...

[velorider]

In Calgary or Edmonton, just put the ball joints on the front porch, then push them in with your fingers...

Ha! That doesn't work in Southern California even in January.

Jan 1st, greenish grass and fresh lemons!!

[oragex]

I believe the freezer sits at -20C (-5F) while some parts of Canada/Alaska get -35C (-30F) in winter, advantage C/A

I also did clean really well the hole from all corrosion with a wire brush on a electric drill and put some high pressure grease in it. Still had to to punch a bit the ball joint in there. Some brands are harder to press in but Lemforder goes in there decently and should be about the only brand to use (it's also the original part that Volvo put in the S60)

[FMradio]

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Thank you very much for this creative ingenious tool! The special tool FCP Euro sells is over 100 bucks. I appreciate you sharing your design and instructions.

I plan to buy an eBay control arm bushing/ball joint combo and replace them on my 06 S60 (or at least attempt to, since I don't have much mechanic experience).

Buying no name eBay parts may be a bad idea, but my car is pretty old and I am not sure if it's worth the money to buy OEM parts. I would like to avoid dangerously crappy parts however. I know it's recommended to replace the entire control arm for ease and simplicity, but since mine is aluminum from factory (vs later S60s that switched to steel), it would feel like a waste to swap it out.

Do you think it's possible to remove that ball joint with just a hammer and pick? Well, I'm guessing it may be possible but probably a huge pain and tiring. I aim to do the job without having to buy extra tools.

[jonesg]

hammer and chisel works for me, installed the same way, I never put them in the freezer, just chisel around the ball joint tappy tap tap.

ebay chinese junk part might only last 6 months..

At least get a harbor freight pry bar and this tool.

[cn90]

The key thing with using PVC pipe coupler:

- Tighten the 2 bolts just a bit. Maybe one full turn just to keep the outer edges down.
- Then tap the PVC pipe a bit
- Then tighten the 2 bolts a bit more...
etc etc

This way the bj goes in evenly.

I don't recommend the PVC round cap, it can shatter with the hammer. Instead, I used a piece of 2x4 wood.

And yes, wear goggles!

I did this whole thing with the steering knuckle in situ.
Info is in XC90 forum.

[vtl]

I did many ball joints with nothing but chisel and PVC pipe, and never needed something better suited. I always use aluminum anti-seize in there as there's a dissimilar metals contacting in the presence of salt water (in New England).

[BlackBart]

I used 2" galvanized pipe with a matching cap, put the ball joint in the freezer, tapped it in nice and straight. No pulling with the bolts.
Done.

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Sideways photos, sorry.

[erikv11]

Last control arm job I did, on the green XC70, I could not get the old ball joint out from one side even after pounding it over and over with the air hammer. Started to chew up the knuckle all around it. I gave up and put it back in, maybe will need to get a new knuckle in order to get a new ball joint in there.