98 f150 4x4 285xxx on body 90k on motor and trans. Had front right ball joint replaced over the summer at a shop and it was replaced with a MOOG. Then, this winter (only 5 months after replacement) that same ball joint started making noise. I looked under and saw it looked like it had cut in half and had no grease in it. I took it back to the shop and they replaced it under warranty for free with a MOOG. Now AGAIN the new one is starting to cut itself. It looks like it is seated lower in the spindle (i think thats what it's called) and causing it to cut open. Could that spindle be worn or did they install the wrong size ball joint possibly? Also I have a popping/thump in the front left wheel area when turning left at slow speeds, in reverse, and accelerating from stop. Not ball joint cause new MOOG on that side that is correctly installed. Thanks for any input its driving me nuts!

 

I've seen it multiple times where people were experiencing the popping/thumping noise and it turns out to be a brake caliper bolt is missing or broken so you may want to try that.. Another possibility could be a bad CV joint.