I have 2000 Chevy Suburban I can’t free lower ball joint from steering knuckle any suggestions ( BROKE : Ball joint separator , tie rode separator) How do I free driver side lower ball joint from steering knuckle?

remove lower ball joint and remove axle nut in the center of spindle. then move the spindle out of the way separating the axle from the spindle.

Hi Douglas, I'm glad to help. My first suggestion is to get to complete shaft. This way you want have any problems later on. It's not that much more expensive and you'll be glad you did. Below is the procedure for replacing them.

FRONT DRIVESHAFTS

REMOVAL

1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Hoisting in the Lubrication And Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
2. Remove the cotter pin and nut lock Hub And Bearing To Stub Axle Retaining Nut from the end of the stub axle.
3. Remove the wheel and tire assembly from the vehicle.
4. Remove the wave washer Wave Washer from the end of the stub axle CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.
   
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut.
6. Remove the two front disc brake caliper to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle Brake Caliper Mounting To Steering Knuckle
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly Correctly Supported Disc Brake Caliper Do not allow the brake caliper assembly to hang by the brake flex hose.
9. Remove the brake rotor from the hub and bearing assembly Remove/Install Brake Rotor
10. Remove nut attaching outer tie rod end to steering knuckle Removing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench.
11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113 Tie Rod End Removal From Steering Knuckle Arm
12. Remove the steering knuckle to ball joint stud, clamping nut and bolt Control Arm To Steering Knuckle Attachment from the steering knuckle.
13. Using a pry bar, separate steering knuckle from ball joint stud Separating Ball Joint Stud From Steering Knuckle Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported.
    
14. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly Steering Knuckle Separation From Driveshaft
15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case Disengaging Inner Tripod Joint From Transaxle Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear.
16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal Tripod Joint Removal from Transaxle When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal.

INSTALLATION

1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand Tripod Joint Removal from Transaxle
3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.
4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle.
5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly Outer C/V Joint Inspection
6. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly Steering Knuckle Separation From Driveshaft
7. Install a new steering knuckle to ball joint clamping bolt and nut Control Arm To Steering Knuckle Attachment Tighten the clamping bolt and nut to a torque of 135 N·m (100 ft. lbs.)
8. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, Removing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 N·m (40 ft. lbs.)
9. Install braking disc on hub and bearing assembly Remove/Install Brake Rotor
10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment Brake Caliper Mounting To Steering Knuckle
11. Install disc brake caliper assembly to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts Tighten the disc brake caliper assembly attaching bolts to a torque of 22 N·m (195 in. lbs.)
12. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut.
13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.)
14. Lower vehicle.
15. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) Torquing Front Stub Axle To Hub Nut
16. Install the spring wave washer on the end of the stub axle.
17. Install the hub nut lock, and a new cotter pin Hub And Bearing To Stub Axle Retaining Nut Wrap cotter pin prongs tightly around the hub nut lock as shown in Hub And Bearing To Stub Axle Retaining Nut
18. Check for correct fluid level in transaxle assembly. Refer to Group 21, Transaxle for the correct fluid level checking procedure for the type of transaxle being checked.
19. Set front toe on vehicle to required specification.

jack up the the side with the broken ball joint under the control arm.
Remove the axle nut (4x4)
remove the caliper and the rotor.
remove the outer tie rod from the knuckle.
Remove the upper and lower control arm nuts and remove knuckle from vehicle.

Using a ball joint press remove and install the ball joint.

tighten axle nut (4x4 only) to 133 lb-ft after everything is assembled.

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

Never use a tool myself other than a big hammer. Those forks don't work for me, though we have them. Hit the joint on the side and it will pop out. If not, you can always put the nut back on even with the ball stud and hit it from the bottom. The book also calls for a special tool to get the axle out of the hub. Have never used this either. If it doesn't slide out, I just hit it--I have a new one anyway (take it loose from the tranny before hitting it). Tools you will need are the big socket for the axle nut (around 22mm or so) and regular metric socket set, preferably 1/2 in drive. Also take the speed sensor and brake lines off the support bracket to free up the hub a little more. Note that you may need to also separate the tie rod end if you cannot otherwise swing the hub out far enough to get the shaft out. The book says to take off the stabilizer and shock and also separate the upper ball joint. I don't know if that's necessary or not, as I have not done one on this particular truck. You are doing the whole shaft, right? We don't do individual CVs anymore, as the labor is ridiculous compared to the cost difference to a whole half shaft. Take the axle nut off, unbolt the shaft from the tranny, and swing the hub out. Pull the axle out of the hub first, then the tranny. Reverse procedure to install. I will paste the book solution from autozone.com below. Lemme know if you have more questions.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   Front wheel and tire assembly Skid plate, as required. If equipped Drive axle hub nut and washer Brake line and wheel speed sensor support bracket from the upper control arm to allow extra travel of the control arm. Left outer tie rod attaching nut and cotter pin. Separate the tie rod from the steering knuckle
   
3. Position the tie rod aside and push steering linkage to the opposite side of the vehicle.
   
   Lower shock attaching nut and bolt; position the shock aside Left stabilizer bar bracket and bushing at the frame Stabilizer bar bolt, spacer and bushings at the lower control arm
   
4. Taking pressure off the upper control arm by placing a support below the lower control arm between the spring seat and the ball joint.
   NOTE Cover the shock mounting bracket and lower ball joint stud with a towel to prevent the axle boot from tearing during removal and installation.
   
   
   Upper ball joint cotter pin and loosen (do not remove) the upper ball joint attaching nut. Separate the ball joint stud from the steering knuckle. Remove the attaching nut.
   
5. Separate the axle shaft from the hub and rotor using tool J-28733 or equivalent.
   
   Axle shaft inner flange bolts and shaft
   

To install:

1. Lubricate the axle and hub splines with an approved high temperature wheel bearing grease.
2. Install or connect the following:
   
   Axle shaft in the hub Inboard CV-joint-to-flange bolts. Torque the bolts to 60 ft. lbs. (80 Nm). Upper ball joint to steering knuckle. Torque the stud nut to 61 ft. lbs. (83 Nm). New cotter pin through the upper ball joint stud and nut, lubricate the ball joint as required. Left stabilizer bar bracket and bushing at the frame Stabilizer bar bolt, spacer and bushings at the lower control arm Lower shock in the mount bracket and the attaching nut and bolt Left tie rod end at the steering knuckle. Torque the nut to 35 ft. lbs. (47 Nm). New cotter pin through the tie rod stud and nut Brake line bracket to the control arm, ensuring the line and/or hose is not twisted or kinked Skid plate, as required Axle hub washer and nut. Insert a drift through the rotor vanes to keep the axle from turning. Toque the hub nut to 180 ft. lbs. (245 Nm) Wheel and tire assembly
   

Here I have the Step by Step :

Wheel and tire assembly Brake caliper and secure it out of the way with a piece of mechanic-s wire. Do not let the caliper hang on the hose. Brake rotor Halfshaft retaining nut and discard it Cotter pin and castellated nut from the tie rod end and separate the tie rod end from the steering knuckle using a suitable removal tool. Discard the cotter pin. Separate the tie rod end from the wheel knuckle ABS sensor bolt and the sensor, if equipped Strut mounting nuts and the studs which attach the strut assembly to the steering knuckle Strut from the steering knuckle Lower ball joint pinch bolt. Carefully pry down on the lower control arm to separate the ball joint stud from the steering knuckle. Wheel hub, knuckle and bearing assembly from the vehicle

Please Rate, Thank you

Removal & Installation NOTE This procedure requires the use of the following special tools: J 9519-E Lower Ball Joint Remover and Installer, J 34874 Booster Seal Remover/Installer, J 41435 Ball Joint Installer, J 45105-1 Ball Joint Flaring Adapter and J 45105-2 Receiver.

1. On 4WD vehicles, remove the wheel center cap and drive axle nut.
   
2. Raise and support the vehicle.
   
3. Remove or disconnect the following:
   
   • Tire and wheel
     
   • Wheel hub and bearing, if necessary
     
   • Outer tie rod retaining nut
     
   • Out tie rod from the steering knuckle using a suitable puller
     
   • Brake hose bracket retaining bolts and bracket
     
   • Upper control arm-to-steering knuckle pinch bolt and nut
     
   • Upper control arm from the steering knuckle
     
   • Lower ball joint retaining nut
     
   • Steering knuckle from the lower control arm using a suitable ball joint removal tool
     
   • Steering knuckle from the vehicle
     
   • Lower ball joint flange with a chisel
     
4. Install tools J 9519-E and J 34874 to the lower ball joint, then use those tools to remove the lower ball joint from the lower control arm.
   

To install:

1. Install or connect the following:
   
   • Lower ball joint to the lower control arm, using tools J 9519-E, J 41435 and J 45105-2
     
2. Remove the tools from the lower control arm.
   
   • Tools J 9519-E and J 45105-1 to the lower ball joint
     
3. Flare the lower ball joint flange with J 9519-E and J 45105-1, then remove the tools from the lower ball joint.
   
   • Steering knuckle to the lower control arm
     
   • Lower ball joint retaining nut and tighten to 81 ft. lbs. (110 Nm)
     
   • Upper control arm to the steering knuckle
     
   • Upper control arm pinch bolt and nut and tighten to 30 ft. lbs. (41 Nm)
     
   • Brake hose bracket to the steering knuckle
     
   • Brake hose bracket retaining nuts and tighten to 7 ft. lbs. (10 Nm)
     
   • Outer tie rod to the steering knuckle
     
   • Outer tie rod retaining nut and tighten to 33 ft. lbs. (45 Nm)
     
   • Wheel hub and bearing, if removed
     
   • Tire and wheel
     
4. Lower the vehicle
   
   • Drive axle nut, if 4WD, and tighten to 103 ft. lbs. (140 Nm)
     
   • Wheel center cap, if removed
     
5. Check the front wheel alignment.
   

hit the steering knuckle where the ball joint shaft goes through it while u have the wedge/pickle fork inserted, u do this on the round side of the knuckle, this is what is called a "Morse Taper" hitting it distorts the hole a little and that lets the joint pop free. You need at least a 5 pound ball pen for this to work..

here is a step by step instructions on how to replace your bearing. please copy and paste the link into your browser for an image.

please do not forget to rate and comment about your experience with fixya today.

Removal & Installation

1. Apply the brakes and hold in place.
   
2. Raise the vehicle.
   
3. Remove the front tire and wheel assembly.
   
4. Remove the cotter pin, lock nut and spring washer from the hub nut.
   
5. While the brakes are applied, loosen and remove the hub nut on the end of the driveshaft.
   
6. Release the brakes.
   
7. Remove the front disc brake caliper and adapter as an assembly, and the brake rotor from the steering knuckle.
   
8. Remove the nut attaching the outer tie rod to the steering knuckle. To do this, hold the tie rod end stud with a wrench while loosening and removing the nut with a standard wrench or crowfoot wrench.
   
9. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB991113.
   
10. Remove the tie rod heat shield.
    
11. Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle.
    
    CAUTION The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during removal. Hold the bolts stationary in the steering knuckles while removing the nuts, then tap the bolts out using a pin punch.
    
12. Remove the two bolts attaching the strut to the steering knuckle.
    
    NOTE Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut.
    
13. Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle.
    
    NOTE Do not allow the driveshaft to hang by the inner C/V joint; it must be supported to keep the joint from separating during this operation.
    
14. Pull the steering knuckle off the driveshaft outer C/V joint splines and remove the steering knuckle.
    
    NOTE The cartridge type front wheel bearing used on this vehicle is not transferable to the replacement steering knuckle. If the replacement steering knuckle does not come with a wheel bearing, a new bearing must be installed in the steering knuckle. Installation of the new wheel bearing and hub must be done before installing the steering knuckle on the vehicle.
    
15. If the wheel bearing and hub need removal. Do not reuse the wheel bearing.
    http://www.chiltonlibrary.com/content/images/32050/images/32050_ptcr_g0035.gif The separation of the ball joint and the knuckle
    

To install:

1. Slide the hub of the steering knuckle onto the splines on the driveshaft C/V joint.
   
2. Install the steering knuckle onto the ball joint stud aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud.
   
3. Install a new ball joint stud pinch bolt and nut. Tighten the nut to a torque of 70 ft. lbs. (95 Nm).
   
   CAUTION The strut assembly-to-steering knuckle attaching bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle.
   
4. Position the lower end of the strut assembly in line with the upper end of the steering knuckle and align the mounting holes . Install the two attaching bolts. The bolts should be installed with so that the nuts face towards the front of the vehicle once installed. Install the nuts. Holding the bolts in place tighten the nuts to a torque of 40 ft. lbs. (53 Nm) plus an additional 90° turn after the specified torque is met.
   
5. Place the tie rod heat shield on the steering knuckle arm so that the shield is positioned straight away from the steering gear and tie rod end once installed. Align the hole in the shield with the hole in the steering knuckle arm. Install the outer tie rod ball stud into the hole in the steering knuckle arm. Start the tie rod attaching nut onto the stud. Hold the tie rod end stud with a wrench while tightening the nut with a standard wrench or crowfoot wrench. To fully tighten the nut to specifications, use a crowfoot wrench on a torque wrench to turn the nut, and a wrench on the stud.
   
6. Tighten the nut to a torque of 40 ft. lbs. (55 Nm). Install the brake rotor, disc brake caliper and adapter.
   
7. Clean all foreign matter from the threads of the driveshaft outer C/V joint. Install the hub nut in the end of the driveshaft and snug it.
   
8. Have a helper apply the brakes. With vehicle brakes applied to keep brake rotor and hub from turning, tighten the hub nut to a torque of 180 ft. lbs. (244 Nm)
   
9. Install the spring washer, lock nut and cotter pin on the hub nut. Wrap the cotter pin ends tightly around the lock nut.
   
10. Install the tire and wheel assembly. Install the wheel mounting nuts and tighten them to a torque of 100 ft. lbs. (135 Nm).
    
11. Lower the vehicle.
    
12. Set the front toe on the vehicle to required specification.
    

http://groups.yahoo.com/group/villagerquest/


Item Part Number Description 1 — Cotter Pin 2 — Nut Retainer 3 1131 Insulator 4 3B477 Front Axle Wheel Hub Retainer 5 1195 Front Wheel Outer Bearing Retainer Washer 6 1104 Wheel Hub 7 1107 Lug Bolt 8 3K050 Snap Ring 9 3123 Front Wheel Bearing 10 2K004 Front Disc Brake Rotor Shield 11 3130 Front Wheel Knuckle

Wheel Hub, Wheel Knuckle and Wheel Bearing SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Tie Rod End Separator T85M-3395-A
Removal

1. Raise and support the vehicle.
   
2. Remove the wheel (1007) and tire assembly.
   
3. NOTE: It is not necessary to disconnect the front brake hose (2078).
   
   Remove the disc brake caliper (2B120) and suspend it with mechanic's wire out of the way. Refer to Section 06-03 for the removal procedure.
   
4. Remove the front disc brake rotor (1125).
   
5. Remove and discard the cotter pin.
   
6. Remove the nut retainer and insulator.
   
7. Remove the front axle wheel hub retainer (3B477) and the front wheel outer bearing retainer washer (1195).
   
   
   
   
   
8. Remove and discard the cotter pin from the front suspension lower arm ball joint (3050).
   
9. Loosen the front suspension lower arm ball joint nut until it contacts the front wheel driveshaft joint.
   
   
   
   
   
10. Strike the front wheel knuckle with a hammer while pulling down on the front suspension lower arm (3078) until the front suspension lower arm ball joint separates from the front wheel knuckle.
    
    
    
    
    
11. Remove the front suspension lower arm ball joint nut.
    
    
    
    
    
12. Remove the front suspension lower arm ball joint from the front wheel knuckle.
    
13. Remove and discard the cotter pin.
    
    
    
    
    
14. Remove the tie rod end nut.
    
    
    
    
    
15. Use Tie Rod End Separator T85M-3395-A to separate the tie rod end (3A130) from the front wheel knuckle.
    
    
    
    
    
16. Remove the front brake anti-lock sensor bolt.
    
    
    
    
    
17. Remove the two front shock absorber-to-front wheel knuckle nuts.
    
    
    
    
    
18. Remove the two front shock absorber-to-front wheel knuckle bolts.
    
19. Remove the front shock absorber (18124) from the front wheel knuckle.
    
20. Use 2-Jaw Puller D80L-1002-L, or equivalent, to separate the front wheel driveshaft and joint (3B436) from the front wheel knuckle.
    
21. Remove the front wheel hub, front wheel knuckle and front wheel bearing as an assembly from the vehicle.
22. If necessary, match mark and remove the steering stop bolt and steering stop bolt jam nut from the front wheel knuckle.
    
    
    
    
    

Installation

1. Position the front wheel hub, front wheel knuckle and front wheel bearing as an assembly on the front wheel driveshaft and joint.
   

1. Install the front wheel knuckle into the front shock absorber.
   

1. Install the two front shock absorber-to-front wheel knuckle bolts.
   

1. Install the two front shock absorber-to-front wheel knuckle nuts. Tighten the front shock absorber-to-front wheel knuckle nuts to 113-123 Nm (83-91 lb-ft).
   
   

The front lower ball joints are pressed into the steering knuckle. Once the brake components are removed, the CV shaft nut and tie rod ends can be removed. Remove the front strut bolts, and the lower ball joint nut. Separate the lower arm from the ball joint. Once the knuckle assembly is off the car remove the lower joint snap ring and dust boot. Utilizing a ball joint press (should be able to rent from local parts store) press the joint out of the knuckle. Re-installation is naturally reverse of removal. I hope this helps.