1994 F-150 4x4, with 4" lift- After replacing all (4) ball joints this weekend, I have positive camber on both sides. 3 degrees on DS and 2 degrees on PS. I am planning on installing an axle pivot drop kit along with camber bushings if needed.
My question is: Will I need to drop the knuckle again to install the camber bushings?

 

If it was a 4" lift on a 94 F150, then it should have had drop brackets included. You'd probably need them for the radius arms too, unless the kit included longer radius arms, which if it did, I'm sure it would have included drop brackets for the front axle. Also, replacing ball joints should not cause the camber change. Was it out of alignment before the change?

When I put my Moog cc824 springs on my truck, it lifted it about 1.5" and I needed -2.75 degree camber bushings to get it back to where it needed to be. A 4" lift would throw you so far out of whack there would be no saving it. So I am skeptical that you (1) have a 4" lift on it, or (2) don't already have drop brackets, or (3) would be seeing only 2/3 degrees out with a 4" lift and no drop brackets. Some pics of your setup here would help clarify what's going on. Before you spend any more money on things you may or may not need.

The answer to your original question is no, technically you do not need to drop the knuckle to replace the camber bushings. It's certainly a lot easier without the ball joint in the way, but it can be driven or pulled out. That's the way they would do it in the shop. They aren't going to drop the knuckle to align it.

 

Thanks! I will try to get some pictures tonight. There was not a noticible camber issue prior to changing the ball joints. Thats what has me so confused. The old ball joints were standard, and not offset.
I assumed it was possible to do the bushings with the knuckle in place, just wanted some back up.

 

Looks like a stock bracket

Front set up. Measured at 3”

Rear set up

 

Those pics don't show us if it has any axle drop brackets....but since it does not have radius arm drop brackets, my guess is that they are not present either.

That "lift" in the front is nothing more than a puck stuffed under the spring. It's causing all of your front end alignment issues, because the TTB cannot be lifted 3 inches without dropping the axles and radius arms to correct for camber and caster. It's hard to tell because some springs just generally look that way, but the coil spring looks to be compressed extremely tight, which would also be a sign of no drop brackets. If those are stock springs they are not supposed to look that way.

The rear is another problem - you have stacked blocks. Its a safety hazard.

My advice would be to remove the puck and remove the aftermarket block (the bottom one) from the rear. Then get it aligned. If you need tie rods or axle pivot bushings, now is the time to do it before you get it aligned.

Lifting these trucks requires a proper kit and what you have can't even be called a half *** attempt - its quarter *** at best. Do it right or take it off. My 2 cents.