What method was used for inspecting/testing the ball joints? It doesn't require a complete failure to affect overall vehicle handling.
Please post your process. A factory authorized or dealer level service tech would use a dial indicator gauge to verify the lateral movement within the ball joint assembly and exactly how much. Anything outside of the specs will result in negative feedback to the steering & chassis, both.
I had another suv 2-years ago that would wander at speeds over 40/50 mph and it was the ball joints failing both times. Don't cheap out on replacement parts when it comes time; it's not an exercise that you want to do, or pay somebody to do, more than once.
If you are really serious about fixing the problem, get a shop manual for your truck and have a go. It has steps and procedure for diagnosing and repair of anything, basically.
Poor Directional Stability
Step Action Yes No
DEFINITION: Driver is unable to maintain consistent, predictable vehicle driving control in any direction.
1
Did you review the General Description and perform the necessary inspections?
Go to Step 2
Go to Symptoms - Suspension General Diagnosis
2
Verify that the directional stability is poor.
Does the system operate normally?
System OK
Go to Step 3
3
Inspect the front stabilizer for the following conditions:
- Stabilizer fasteners for looseness
Refer to Fastener Tightening Specificationsin Front Suspension.
- Worn or damaged stabilizer or stabilizer bushings
Refer to Stabilizer Shaft Replacement in Front Suspension.
- Damaged or missing stabilizer links
Refer to Stabilizer Shaft Link Replacement (2500) in Front Suspension.
Did you find and correct the condition?
Go to Step 10
Go to Step 4
4
Inspect the following suspension and steering components for wear or damage:
- Control Arms
Refer to Upper Control Arm Replacement or Lower Control Arm Replacement in Front Suspension.
- Ball Joints
Refer to Ball Joint Inspection (Lower Ball Joint) | Ball Joint Inspection (Upper Ball Joint).
- Tie rod ends
Refer to Tie Rod Replacement in Steering Linkage or Rear Wheel Steering Inner Tie Rod Replacement or Rear Wheel Steering Linkage Outer Tie Rod Replacement in Rear Wheel Steering.
Did you find and correct the condition?
Go to Step 10
Go to Step 5
5
Inspect the wheel bearing. Refer to Wheel Bearings Diagnosis.
Did you find and correct the condition?
Go to Step 10
Go to Step 6
6
Inspect the vehicle trim height. Refer to Trim Height Inspection.
Did you find and correct the condition?
Go to Step 10
Go to Step 7
7
Inspect the steering column for looseness. Refer to Looseness in Steering Column in Steering Wheel and Column.
Did you find and correct the condition?
Go to Step 10
Go to Step 8
8
Inspect the steering gear for the following conditions:
- Steering gear mounting bolts for looseness
Refer to Fastener Tightening Specificationsin Power Steering.
- Pitman shaft over-center adjustment
Refer to Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off Vehicle in Power Steering System.
Did you find and correct the condition?
Go to Step 10
Go to Step 9
9
Inspect and adjust the wheel alignment as necessary. Refer to Wheel Alignment Measurement (w/Rear Wheel Steering) | Wheel Alignment Measurement (w/o Rear Wheel Steering) in Wheel Alignment.
Did you complete the alignment?
Go to Step 10
—
10
Operate the vehicle in order to verify the repair.
Did you correct the condition?
System OK
Go to Step 3
Ball Joint Inspection (Lower Ball Joint)
Special Tools
J 8001 Dial Indicator Set
Click to Enlarge
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
- With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions.
- Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation.
- Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Lower Control Arm Ball Joint Replacement (Coil Spring Suspension) | Lower Control Arm Ball Joint Replacement (Torsion Bar Suspension).
- Install and position the dial indicator from J 8001 Dial Indicator Set against the end of the ball joint.
NOTE
Important
Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD).
Gently lift or pry the suspension upward then let it settle.
- The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification, replace the ball joint.
Ball Joint Inspection (Upper Ball Joint)
Tools Required
J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 Dial Indicator Set
Click to Enlarge
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
- With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions.
- Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation.
- Support the lower control arm with a floor stand or jack, as far outboard as possible.
- If a seal is cut or torn, replace the ball joint.
- Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Upper Control Arm Replacement.
- Check the wheel bearing for looseness in the wheel bearing is present. Refer to Wheel Bearings Diagnosis.
- Check the upper ball joint for vertical looseness.
- Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded.
- Install and position the dial indicator from J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 | J 8001 against the rim of the upper ball joint.
- Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the upper ball joint.
- Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is too high, replace the upper control arm. Refer to Upper Control Arm Replacement.