Defender 90 NAS - rear a-frame ball joint replacement question

[lcdck]

Planning on replacing the rear a frame ball joint this weekend. The fuel tank is in the way of getting good access. Any tips or warnings before I start? How bad of a job is it? There seems to be almost no info in the manual.
I bought the Glen Lewis replacement so I don't have to press anything out.

 

[JimC]

It’s not bad if the long bolts to the a frame come out ok. You can hack into the big nut on the ball joint if you need to - no need to worry about saving the old. Jack the frame up a bit to improve access, no need to worry about putting the joint under load, if things get tight you can just use a pry bar to rotate the axle a bit. It should all drop back together pretty easily, just ensure you get the big castle nut tight enough.

 

[erover82]

If you’re doing a Rover rear axle it can be tough to get a tool on the castle nut. I ground a socket down to both break it loose and later use a torque wrench to fasten.

 

[JimC]

I just use a drift and hammer on the big nut if I’m replacing it. If it’s really bad you can dremel down opposite sides and break it.

 

[Siia109]

I did mine and I had it on the bench / Axle stand and it was a PITA. It was a Salisbury axle and the castle nut was not budging - I had the axle upside down with penetrating fluid on it over night to crack it loose - I think I eventually took the grinder to it. All I kept saying is - how would you do this laying on you back under the truck trying to swing a ball peen hammer and holding the chisel just so....

As this was my first time doing this a-frame - I am now looking at doing it to my D90 and thinking - maybe I should just drop the axle out and do a rebuild of the entire rear end... Good luck and let us know how it goes.

 

[jymmiejamz]

I use an air hammer on the big nut if I can’t get it with an impact

 

[rocky]

It’s one of those sonnofabitch jobs. If anyone is planning to replace the chassis on their truck, that’s probably the best time to do it. Much better access.

 

[lcdck]

Got it done. It wasn't the worst job I've had to do on a defender but I hope I don't have to do it again, at least not on this truck. Removing the ball joint from the axle was probably the easiest part. The long bolts going through the frame were seized and getting them off was a multi-session job involving air hammers and my big impact driver. The Glen Lewis ball joint appears to be a good upgrade but only time will tell.