I recently bought my 2004 FX4 (supercrew, 180K miles) and it turns out I need some front end work. I currently have a 6" lift from Zone Offroad, including a big spacer at the top of my strut towers in front. Tire size is 35x12.5.

Here is the list of items that need to be addressed:
1. Ball joints (at least lower left and upper right) are worn and have play
2. Front Diff makes noise when turning at low speed in 4WD
3. IWE Solenoid is the old model (no moisture barrier)
4. Front Brakes are worn, rotors are rusty and squeak, calipers are rusty
5. Front Right ABS sensor has been clipped off - maybe snagged something? but is missing...

The axles and steering assembly looks like they are in OK shape, a little rusty, but no cracks in boots etc.

I've already got the new IWE solenoid and plan to do that when it arrives, so its possible my front diff troubles get solved between that and a fluid change, but I will know more when I get the diff open.

I was thinking I should just take a saturday and take it all apart, but the more I research the less I know how far to go...I could replace ONLY the broken stuff (ball joints, brake pads and rotors), and hope the rest holds up. OR, I could try to replace most everything that might go bad while I am in there. I am not looking for serious performance gains, my goal isn't hardcore offroading, but I did buy a 4x4 for a reason - it should be capable within reason off road.

I am leaning towards the following, but want to get feedback from the enthusiasts here:
1. Replace strut+spacers with RC struts designed for 6" lifts
2. Replace Upper Control Arms (figure this is more time/cost effective than pulling ball joints)
3. Replace Lower Ball Joints (LCAs are pricier, ill do the ball joints)
4. Replace Rotors
5. Replace Pads
6. New ABS sensor

I could use advice on other items to replace "while its all apart", as well as any advice on specific brands or parts for replacement if there are suggestions.

Thanks in advance!

 

At 16 years old you're going to want to replace the bushings too. Get loaded lower control arms. Getting the old ones out is a nightmare. Been there done that.

 

For your upper ball joints, I'm glad you want to buy control arms. Because that's the only way to service them, the ball joint is integral to the UCA

 

Ah fair point, I was just surfing rock auto and found them sold individually: https://www.rockauto.com/en/catalog/...ll+joint,10070

 

What you posted was for front lower ... like Mustang said the uppers are not serviceable... you replace the whole UCA...
I suggest Moog problem solvers for all the ball joins and end links.