So, last weekend Ben (Swatchie) and I did all four ball joints, two tie rod ends, and the axle pivot bushings on my Bronco. We used the Autozone loaner ball joint press, which isn't exactly the right tool for this job. However, with a little creativity, you can make it work.
Ian already has a great writeup for how to do ball joints, but he had a machine shop do the press work for him. I highly recommend starting with his writeup: http://www.fullsizebronco.com/forum/...ad.php?t=45983
Once you've read that, here's how to press them in and out yourself using the imperfect loaner tool:
Here's the knuckle removed from the truck. The left of the picture is the top. We cut the upper stud while we were figuring out how NOT to use the press.
The bottom of the knuckle. The lower joint has a snap ring that you must remove. The upper joint does not, although the new kit will come with one that you won't use.
This is NOT how you press out the bottom joint.
THIS is how you press out the bottom joint. By the way, you must press the bottom joint out first.
Both joints removed. We coated the bores with anti-seize before installing the new joints.
Press the upper joint in first. This is how you set the press up; there's a lip on the joint and one of the cups should fit right onto it. We used a radius arm washer on the bottom so that there was something for the press to, well, press against.
You'll run the threaded rod through the lower joint's bore. This is why you install the upper first.
Once you've bottomed the joint against the tool (it won't be fully seated in the bore), you'll need to hammer it in the rest of the way. Notice that we've got two cups stacked up; you'll have to do this with the Autozone tool because the stud is longer than the installing cup. When it's fully seated, it will stick out the bottom of its bore about 1/16".
Here's how to set up and press in the lower joint. Don't forget to install the new snapring.
And now you're done! A big thanks to Ben for all of his help. And here he is busting a nut: