This article describes how to seperate tie rod ends (knuckles) and is applicable to all the steering components (ball joint, pitman arm, etc.) that have a ball joint type joint or knuckle.

Important: You should wear protective clothing and eyewear whenever working on suspension components. Use caution and make sure you have a safety plan in case of emergency.

Tools

The original tool used by VW is no longer available, but there are several variations that are similar to the original design.

First, a tool that I would not recommend is the JCWhitney Screw Type Ball Joint Remover. This tool is worthless in my opinion. It cost $9 + $9 shipping and does not do the job. It is hard to keep mounted on the joint/union area. The bolt that is used to push out the tie rod bolt, spins off when tightened (it should be bigger with a recessed end or have a welded on flat cap to increase surface area). This is one of those tools that seems "fashioned" after an original tool - but not produced by a tools company. (A VintageBus listee reported that the bolt used with the tool bent during use.)

Two resellers, Pelican Parts Inc. and Samstag Sales, sell a seperator that is similar to the original factory tool - both suppliers price the tool similarly at $46 and $42 respectively. Click on the links for pictures of this style of tool.

A variation on the original theme is available that uses a fulcrom method to apply more force to the ball joint stud. You can also purchase this tool in the UK through Machine Mart and on the internet through the Tools Warehouse.

A tool that is not designed for ball joint separation, but can be used for this purpose, is a gear puller. A small size gear puller can also be used to remove the pitman arm. Its flexibility in design makes it adaptable for various sizes of ball joints - rather than being a tool specifically for this purpose. This tool and most of the tools (and variants) mentioned above are available at the Tools Warehouse.

Seperating the tie rod using brute force

A brute force tool used to separate ball joints is the "pickle" fork. The pickle fork is a common tool sold under many brand names. Lisle Corporation sells most of the tools you'll find at the local automotive parts stores. Their suspension tools page has illustrations of how these various tools are used. One downside of the pickle fork is that it destroys the boot during removal. So, if you like to save parts for emergencies, this is not the tool to use. (But the tool that is most easily available.)

The "two hammer method" uses a stationary hammer (or heavy piece of metal) and a moving hammer to knock the tie rod bolt loose. This method is described on the Porsche 928 Suspension FAQ page.

Some people suggest prior to using this method to heat up the area with a torch - which causes an expansion of the hole that the tie rod bolt fits through. This method is described in an entertaining way in the Type2 library. Ball Joint Removal from Torsion Arm by Steve Denis and Al Brase.

The procedure

There are many sites that demonstrate how to separate tie rods. Most automobiles, no matter what marque, use a ball joint or tie rod configuration that is very similar to the Volkswagen.