2003 Explorer 4WD suspension

Had to replace the rear bearing and hub assembly. All instructions mentions to be careful and not tear upper control arm boot. I think it's impossible not to tear. Well, it tore slightly. Suggestions on how to prevent it from tearing since I will need to do other side soon? Ford does not sell boot as separate item, sold only as control arm assembly (ball joint, boot and arm) $285.00. A bit much for only a boot plus the time to replace and a wheel alignment. I thought about finding a replacement boot. Only place I came close was Energy Suspension but one has to measure the joint since there is no fitment chart for that joint. Anyone have an old arm laying around and can measure? Any one have a solution or have encounter this problem? Thanks in advance.

It appears from the service manual that that is not a tapered shaft on the joint. The 2002 service manual shows a bolt going though the knuckle which holds the ball joint in. Do you recall if your 2003 is the same, and the shaft of the ball joint has a concave ring around it that the bolt will run along? I'm struggling to describe this, hopefully it makes sense to you.

If that's the case, you shouldn't need a pickle fork to separate the joint from the knuckle. I'm guessing a pickle fork is what's causing the boot to get damaged. You should be able to give the arm a pretty good whack with a dead blow hammer from underneath and pop it loose if there isn't a lot of corrosion in that area.

Keep in mind that I have not been fortunate enough to need to do one of these on a newer Explorer, so there may be reasons you can't do what I suggested.

-Rod

The shaft of the ball joint is tapered and also has the concave ring on the shaft. The bolt rides on the ring/groove after being inserted thru the bolt hole which is part of the knuckle. I did use pickle fork after removing the bolt and got a small tear of the boot. I'll try the soft blow hammer on the other side when it's time. No corrosion in my area in CA.