Go Back   Horizons Unlimited - The HUBB > 4 wheels > 4WD Overland Tech

4WD Overland Tech GENERIC 4WD / 4 wheel TECH discussions and info that is valid for ALL brands. See brand specific forums.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Visit Matt Savage for VIAIR compressors, Air Lift Helper Springs, Tyre Levers, Chris Scott's Books & DVDs, KC Daylighters, Allisport Intercoolers, Overland Preparation and lots more!

LinkBack Thread Tools Display Modes
Old 2 Sep 2012
nomadic's Avatar
Registered Users
HUBB regular
Join Date: Jun 2011
Posts: 47
Thumbs up Ball joint removal - The Fight

The dust covers on the steering rod of my 1719AK truck needed replacement - a simple procedure which turned out into one hell of a fight.

The conical shaped pin just couldn't be convinced to exit the socket in the steering rod. Hammering, heavy jack lifting, heating by torch, cursing - nothing worked.

After 3 mornings of trying I had to resort to specialized tools to get the job done - an impression if nothing else works;

Ball joint separator tool for dust cover replacement

With the ball joint separator tool from Kukko it was a 1 minute job....
Overland by 4x4 truck
Reply With Quote
Old 4 Sep 2012
Dodger's Avatar
Large Golden Member
Veteran HUBBer
Join Date: Aug 2005
Location: BC, Canada
Posts: 1,098
A trick I was shown many moons ago ,which has NEVER been known to fail in over 30 years -

You use two hammers , one a small sledge and the other is a 2lb or slightly bigger ball pein .

Slacken off the nut most of the way .
Place the large hammer behind the tapered ball joint female part , touching it and apply enoough pressure to hold the hammer in place .
Whack the ball joint "female part " with the smaller hammer directly opposite the large hammer .
You might have to give it several blows ,but the ball joint tapered part will pop out of the tapered female housing .

What happens is the large hammer acts as an anvil and the smaller hammer blows cause the female taper to distort slightly and break the "seal".

This method is extremely useful if you want to dismantle the joint without damaging the rubber cover .

It is obvious from your photo that whacking away willynilly on the arm did not work and in some cases could cause damage to the steering arm . You simply do not need brute force to separate the parts and you should never beat on components like that .
If it's a fight - you're doing it wrong .

When you refit , apply grease or copper coat to the taper .

Hope this helps .
Blessed are the cracked, for they let in the light. - Spike Milligan
"When you come to a fork in the road ,take it ! When you come to a spoon in the road ,take that also ."
Reply With Quote
Old 4 Sep 2012
nomadic's Avatar
Registered Users
HUBB regular
Join Date: Jun 2011
Posts: 47
Hi Dodger,

Thx for the reply & info.

Used this particular technique - what happens is that the 'vice' hammer bounces on the other side on the blow with the smaller hammer. Creates sort of a rhythm. A mechanic from a car workshop came up with this.

Had a look at a nearby tractor (Kubota / John Deere) workshop, there they took out a huge sledgehammer for the reluctant cases. Didn't want that anywhere near my 1719 steering rods!! Plus side for tractors, the ball joints are easily accessible. For a Mercedes 1719 it's not.

The Kukko ball joint puller then showed the frightening amount of force necessary to push out the conical pin. It came out with an explosive snap. With hindsight i really doubt any hammering would have done it. The pin & socket were totally dry, prolly not greased at all when put together again many many years ago.

The Kukko tool is well worth it's price - a workshop session is more expensive, not even added the fuel to get there & away.

Overland by 4x4 truck
Reply With Quote

ball joint dust cover

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
XT600E Carb Removal? TheBaldReverend Yamaha Tech 23 7 Jun 2013 10:50
1981 KL250 front wheel removal Kumuya Kawasaki 3 8 Jun 2012 21:22
fight the northen Thai seasonal burnings! mamos Southern Asia 0 18 Mar 2012 13:48
Headers to silencer joint awolxt Yamaha Tech 22 11 Mar 2012 19:47
DR 350 fuel canister removal Dazzle Suzuki Tech 1 9 Jan 2012 14:59


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

Check it out at the HU Store! Remember to use Coupon Code 'HEROES' on your order when you checkout.

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 02:41.