Lower Ball Joint Gen II FSM minimalist rewrite

Abstract: Front wheel bearing replacing.
Applies to: 2004 through 2009 Model Year Prius:
Real world 30 year experience tips added, non sterile less than well equipped shop rewrite version by an aircraft tech. Tip: use of 50/50 beauty store acetone / Dextron III ATF mix on rusty hardware it's the best rust dissolver on the planet that is not an powerful acid and salvage yard helper (we call majic pink stuff) that we have ever used. Make up a QT in a high quality polyethelyne garden spray bottle. Use: presoak / spray from minutes to 2 weeks depending of severity i.e. very old rusty exhaust hardware need a couple weeks and once to twice daily application for best results) but take great care to keep off rubber(s) control arm bushings etc seals, plastics anything not metal it can dissolve or swell and off areas of rotors brake pads (as it ruins them and is very dangerous), bearings as it creeps and is a incredible lubricant destroying / removing solvent. Shake some immediately before using. Take care its flamable and will hurt your eyes badly!
What follows "Not Req'd" can be omitted & done on vehicle until "Req'd" and can be accomplished sometimes by a few different methods with a minimally, moderately to well equipped shop, mechanic, shade tree i.e. one alt't method listed in notes.

Bend out lock (grinding on a smaller chisel to fit axel.groove is recommended) & loosen 30mm 12 point axle nut first! 3/4 drive tools are recommended in rust belt or over 80k mi with force downward. OD clearance for socket in rotor ID is about 1.752", a 1 1/4" 12 point will work but we found 30mm axle socket, thin wall, in 1/2 dr (and used a 1/2" to 3/4" female impact adapter & 3/4" drive ratchet / breaker) $ 8.99 made in Tiawan socket only one available in correct config not too large OD in Tulsa at Steves Wholesale Tools. Proto 3/4 sockets in shallow are ~.250" ish too shallow & too large OD.
Break loose wheel mount nuts.
Then:
Raise and support vehicle safely.
Remove wheel stud nuts & front wheel.
Optional if more travel is desired /Not req'd:
Remove front wheel speed sensor. Req'd
Remove front brake caliper mounting bolts (arrows) and brake pad if fitment is loose and it may fall out.

Optional:
Install one lug nut to keep rotor disk from moving if it is not stuck.

Remove and suspend brake caliper using stiff wire.
Remove front brake rotor.
Remove tie rod end from steering knuckle.
Reqd:
Remove steering knuckle to strut bolts.
Remove drive axle shaft outboard end from rotor splines carefully.
Remove lower ball joint fasteners and seperate ball joint from lower control arm. Use of air chisel on flange of castle nut may be req'd. Use of 3'-4' 4130 alloy 1 3/4"-2" pipe or large prybar set may be reqd to pry down on lower control arm.

Not req'd but see note:
Remove steering knuckle from vehicle.
Mount steering knuckle in vise. NOTE: If you do not remove steel pressed in dust boot removing ball joint stud nut can be far more difficult and access to castle nut is restricted to open end 19mm and rounding off castle nut is likely. If joint stud turns remove by cutting out LBJ boot and vise grip the stud. Using a flat bladed screwdriver remove axle dust boot.

Not required but see Note::
Using a ball joint press, remove ball joint from steering knuckle. NOTE: ALt't methods include forks & air chisel / hammer / rivet gun ball joint remover forks.

Remove wheel hub fasteners (arrows) and remove wheel hub from steering knuckle.
Stop of not Req'd.

Installation is reverse of removal.
Torque Specifications (added wet torque reductions if care is taken to preclean thoroughly and hardware are in VGC. Remember the military states there are over 62 factors that can affect torque).

Check disk rotor shield(s) as applicable for clearance ti disk as they are thin and get bent and rub making high pitch noises.

Front wheel hub to steering knuckle
56 Nm (41 ft-lb) add antisieze =wet (39 ft-lbs ~ish)

Front lower ball joint to steering knuckle (castle nut)
71 Nm (52 ft-lb) add antisieze =wet (49.4 ft-lbs)

Lower ball joint to control arm dry
89 Nm (66 ft-lb) add antisieze =wet (62.7 ft-lb)

Front strut to steering knuckle
153 Nm (113 ft-lb) add antisieze =wet (107.4 ft-lbs)

Front brake caliper to steering knuckle
109 Nm (81 ft-lb) add antisieze =wet (77 ft-lbs).

Front axle nut to wheel hub
216 Nm (159 ft-lb) add antisieze =wet (151.1 ft-lbs). Recommend driving 5 miles but no more and rechecking on level ground with vehicle weight on wheel before locking tab in groove.

Wheel to wheel hub
103 Nm (76 ft-lb) add antisieze =wet (72.2 ft-lbs) Recommend driving 5 miles no more then rechecking on level ground with vehicle weight on wheel.

Tie rod end lock nut
74 Nm (54 ft-lb) add antisieze =wet (51.3 ft-lbs).

Ties rod end to steering knuckle
49 Nm (36 ft-lb) add antisieze =wet (34.2 ft-lbs).
Disclaimer: Use at own risk. Use shop & maintenance best practices.

Taking suggestions on this, but keep in mind it is just an alternate method with minimalist removal. Will edit as my young adult sons performed the job with consulting from me 3 times mainly due to the axle dust boot obstructing LBJ stud nut access. We own a press and every tool to do this the FSM way but prefer to do it other ways like today during very cold temps & blowing, pouring rain. Hope this helps someone.

For those wanting FSM with pics it's here on Bentley's site:
Confluence Mobile - Bentley Publishers Support

 

Thank you.
Just edited to clarify optional removal of speed sensor from not reqd as son said he removed it to get more comfortable play room to remove axle shaft and change to Reqd on brake caliper outboard pad removal. Added using one lugnut to hold rotor from moving if its not stuck. Lastly check of disk shield added.

 

I plan on doing the same for CV axle halfshaft R & R when we do it as at least one of or '04 shafts is clicking. Might include pics if someone thinks they are necessary.

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