Mechanics

JAGUAR XJ8 BALL JOINT PROBLEM

2002 Jaguar XJ8 • V8 2WD Automatic • 77,778 miles

How to install front lower ball joint
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Jaguarstone01
November 27, 2010.




Removal
CAUTION: Replacement of nuts and bolts: Various thread-locking devices are used on nuts and bolts throughout the vehicle. These devices restrict the number of times a nut or bolt can be used. See GENERAL INFORMATION article for further information.

CAUTION: The ball joint must be returned for warranty purposes, care must therefore be exercised to avoid damaging it during removal. Any damage incurred during removal must be noted and recorded.

Raise front of vehicle.
Fully slacken adjuster nut of special tool 204-114 and position tool in center of road spring.
Fig. 7: Identifying Special Tool Adjuster Nut
Courtesy of JAGUAR CARS, INC.
Lower front of vehicle.
WARNING: ENSURE THAT THE DOWEL OF TOOL 204-114 IS CORRECTLY POSITIONED ACROSS THE SUSPENSION TURRET SLOT.

Locate special tool in suspension turret slot.
Pass special tool 204-114 through slot in suspension turret and rotate stem to locate dowel.
Fig. 8: Locating Special Tool In Suspension Turret Slot
Courtesy of JAGUAR CARS, INC.
WARNING: WHEN TIGHTENING TOOL NUT, USE LOWER DOWEL AS A GUIDE TO ENSURE THAT THE TOOL STEM DOES NOT ROTATE AND DISTURB POSITION OF DOWEL IN SUSPENSION TURRET.

Fig. 9: Tighten Nut Of Special Tool
Courtesy of JAGUAR CARS, INC.
Tighten nut of special tool 204-114 to full extent, to achieve suspension mid-laden position.
Raise front of vehicle and support on stands.
Remove appropriate road wheel.
Remove and discard tiestraps securing wheel speed sensor harness to upper wishbone.
Fig. 10: Removing Wheel Speed Sensor Harness-To-Upper Wishbone Tiestraps
Courtesy of JAGUAR CARS, INC.
Move steering to appropriate full lock for access to suspension.
Remove nut securing upper wishbone ball joint to vertical link.
Fig. 11: Removing Nut Securing Upper Wishbone Ball Joint To Vertical Link
Courtesy of JAGUAR CARS, INC.
CAUTION: Do not use special tool 211-098 in the following procedure as this will damage the ball joint gaiter.
Release wishbone ball joint from vertical link.
Install special tool 204-192 on upper wishbone ball joint.
Tighten bolt of special tool to release ball joint taper from vertical link.
Fig. 12: Releasing Wishbone Ball Joint From Vertical Link
Courtesy of JAGUAR CARS, INC.
Remove special tool from ball joint.
Lift upper wishbone to withdraw ball joint from vertical link.
Fig. 13: Lifting Upper Wishbone To Withdraw Ball Joint From Vertical Link
Courtesy of JAGUAR CARS, INC.
To prevent damage to lower ball joint, secure vertical link to road spring using strong wire.
Fig. 14: Securing Vertical Link To Road Spring Using Strong Wire
Courtesy of JAGUAR CARS, INC.
Remove upper wishbone fulcrum nut and bolt and withdraw wishbone from vehicle.
Fig. 15: Removing Upper Wishbone Fulcrum Nut And Bolt And Withdraw Wishbone From Vehicle
Courtesy of JAGUAR CARS, INC.
Secure upper wishbone in a vise.
Using a hacksaw, partially cut through two diametrically opposite segments of ball joint flange.
Fig. 16: Cutting Through Diametrically Opposite Segments Of Ball Joint Flange
Courtesy of JAGUAR CARS, INC.
Carefully chisel through and remove the two ball joint flange segments to permit installation between press bed plates.
Fig. 17: Removing Ball Joint Flange Segments To Permit Installation Between Press Bed Plates
Courtesy of JAGUAR CARS, INC.
Remove wishbone from vise and thoroughly clean to remove swarf and road deposits.
For warranty purposes, paint positions of spring clip ends on ball joint housing and rubber gaiter.
Fig. 18: Painting Positions Of Spring Clip Ends On Ball Joint Housing And Rubber Gaiter
Courtesy of JAGUAR CARS, INC.
NOTE: Any gaiter damage incurred during removal must be recorded for warranty purposes.

Remove retaining clips and gaiter.
Exercising care to avoid splitting or otherwise damaging gaiter, remove retaining clips.
Remove gaiter and retain for warranty purposes.
Fig. 19: Removing Retaining Clips And Gaiter
Courtesy of JAGUAR CARS, INC.
Invert wishbone and position on press with ball joint flange between press bed plates.
Fig. 20: Inverting Wishbone And Positioning On Press With Ball Joint Flange Between Press Bed Plates
Courtesy of JAGUAR CARS, INC.
Install special tool 204-200 on ball joint and operate press to release joint from wishbone.
Fig. 21: Installing Special Tool 204-200 On Ball Joint
Courtesy of JAGUAR CARS, INC.
Remove special tool from ball joint.
Remove ball joint and wishbone from press.
Ensuring that their relative positions are clearly marked, place ball joint, rubber gaiter and retaining clip in a clean plastic bag and return for warranty purposes.
Thoroughly clean wishbone paying particular attention to ball joint and pivot bolt locations.
Installation
Install ball joint in wishbone.
Position support of special tool 204-199 on press bed and place wishbone on tool.
Using ball joint plastic cover to align, position mandrel of special tool 204-199 on ball joint
Align assembly with press ram and operate press to fully seat ball joint in wishbone.
Fig. 22: Installing Ball Joint In Wishbone
Courtesy of JAGUAR CARS, INC.
Remove tool mandrel 204-199 from ball joint.
Remove wishbone and support tool 204-199 from press.
Position wishbone on suspension beam, install fulcrum shaft thread rearward, install nut and tighten to 60-80 Nm.
Fig. 23: Installing Fulcrum Shaft Thread Rearward And Nut
Courtesy of JAGUAR CARS, INC.
Remove wire temporarily securing vertical link to road spring.
Fig. 24: Removing Wire Temporarily Securing Vertical Link To Road Spring
Courtesy of JAGUAR CARS, INC.
Remove and discard plastic cover from ball joint.
Position wishbone to engage ball joint taper in vertical link.
Fig. 25: Positioning Wishbone To Engage Ball Joint Taper In Vertical Link
Courtesy of JAGUAR CARS, INC.
Install nut securing ball joint to vertical link and tighten nut to 60-80 Nm.
Fig. 26: Installing Nut Securing Ball Joint To Vertical Link
Courtesy of JAGUAR CARS, INC.
Reposition wheel speed sensor harness on wishbone and secure with two tiestraps.
Fig. 27: Repositioning Wheel Speed Sensor Harness On Wishbone And Securing With Tiestraps
Courtesy of JAGUAR CARS, INC.
Install road wheel.
Raise vehicle, remove stands and fully lower vehicle.
Fully slacken nut on special tool 204-114.
Fig. 28: Slackening Nut On Special Tool 204-114
Courtesy of JAGUAR CARS, INC.
Release dowel of special tool from suspension turret slot.
Fig. 29: Releasing Dowel Of Special Tool From Suspension Turret Slot
Courtesy of JAGUAR CARS, INC.
Raise vehicle for access and remove special tool from suspension.
Fully lower vehicle.
Carry out steering geometry and wheel alignment checks and if necessary adjust. Refer to SPECIFICATIONS & PROCEDURES article.

Dr Loot
Nov 27, 2010.


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