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Matt:
I repalced the ball joints on my 745t earlier this year. Below is the description (the best I can remember) of how I did it.
1. Loosen lug nut on front wheels.
2. Set parking brake and block rear wheels. Raise car and support on jack
stands placed under subframe.
3. Remove wheels.
4. Remove cotter pin or retaining clip from threaded portion of ball
joint,loosen and remove large nut holding tie rod to ball joint.
5. Separate tie rod form ball joint using fork type pry bar. At this point
you will most likely need some type of long pry bar to push tie rod end
down far enough to remove it completely from the ball joint.
6. Loosen two bolts holding ball joint to lower strut tube.
7. Remove ball joint. A couple soft wacks with a rubber mallet might
be necessary to break the ball joint loose from the strut tower after
the two bolts have been removed.
8. Install new ball joint on strut tube using the bolts provided. Be sure
to use some lock tite on the threads. If I remember correctly, the MOOG
ball joint I purchased came with some red lock tite. Do not hold me to
this about the color. But use some. Torque bolts down to spec.
9. Use the long pry bar to push tie rod end down far enough so as to get it
back on the ball joint. Extra pair of hands could be helpful here.
10.Install new nut that holds tie rod onto ball joint and tighten to spec.
It will probably be necessary to use the long pry bar to push up on tie
rod end to prevent threaded portion of ball joint from spinning while
you are tightening the nut. Replace cotter pin or retaining clip.
11.Reinstall wheel, lower car and enjoy nice ride and steering.
12.Get front end aligned
Hope this helps and good luck.
Disclaimer: In light of the recent oil pan drain lifting syndrome, the above information is presented only as a recommendation and should not be cosidered the final word on how it is done. I am not a professional mechanic. I provided the information in an attempt to help fellow Brick owners as a way of saying thank you to the Volvo community using the Brickboard who have helped me keep my Brick rolling happily along.
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