Recall - Lower Ball Joint Replacement
99-023March 26, 2001
Applies To:
1996-98 3.5RL - See VEHICLES AFFECTED
1996-98 2.5TL/3.2TL - See VEHICLES AFFECTED
1997-98 2.2CL/2.3CL/3.0CL - See VEHICLES AFFECTED
Safety Recall: Lower Ball Joints
(Supersedes 99-023, dated June 15, 1999)
BACKGROUND
Certain vehicles were manufactured with front suspension lower ball joints that may prematurely wear out. In the worst case, the ball joints would separate without prior warning, causing the front suspension to collapse.
VEHICLES AFFECTED
CUSTOMER NOTIFICATION
All owners of affected vehicles will be mailed a notification of this recall. An example of the customer notification is at the end of this service bulletin.
CORRECTIVE ACTION
Replace the front suspension lower ball joints.
PARTS INFORMATION
Ball Joint Kit, 3.5RL: P/N 04510-5Z3-000
Ball Joint Kit, 2.5/3.2TL: P/N 04510-5L5-000
Ball Joint Kit, 2.2/2.3/3.0CL: P/N 04510-S84-000
Front Knuckle Ring, 3.5RL & 3.2TL:
P/N 51212-SP0-000
REQUIRED SPECIAL TOOLS
Heavy-Duty Hub Puller: Snap-on P/N CJ-129
Old Forge P/N 2518
NOTE:
Heavy-duty hub pullers can be purchased through the Honda Tool and Equipment Program at (888) 424-6857.
Ball Joint Remover/Installer Tool Set:
The individual tools do not have tool numbers; each tool is stamped with a letter for reference.
WARRANTY CLAIM INFORMATION
REPAIR PROCEDURE
NOTE:
Wear eye protection during the entire procedure.
Ball Joint Removal
1. Raise the vehicle on a hoist. Remove the front wheels.
2. Remove and discard the spindle nut.
3. Remove the cotter pin and castle nut from the lower ball joint. Discard the cotter pin.
4. Separate the lower control arm from the ball joint with the special tool. To avoid damaging the ABS sensor harness, do not let the knuckle hang by its weight.
5. Remove the axle from the front wheel hub. If the axle is stuck to the hub, go to step 6. If the axle comes out easily, go to step 9.
6. Reinstall the knuckle on the lower control arm and loosely install the castle nut.
7. Using a heavy-duty hub puller, free the axle from the hub. Do not press it all the way out.
8. Remove the castle nut, lift and support the knuckle (to prevent damaging the ABS sensor wire harness), and press the axle out of the hub.
9. Lift the knuckle, then place a block of wood (about 2-3/4" x 1-1/2" x 5") between the upper control arm and the damper assembly.
10. Remove the boot from the lower ball joint.
11. 3.5RL and 3.2TL only: Remove and discard the knuckle ring.
12. 2.5TL and CL only: Remove the brake caliper mounting bolts and the caliper. Remove the four flange bolts, then remove the brake rotor/hub assembly.
13. Clean the recessed area around the ball joint with solvent and compressed air, then install the base remover adapter (Tool C, D, or F).
14. Hold the remover installer adapter (Tool A) up to the ball joint, then install the castle nut to hold it in place. Install the remaining special tools on the lower ball joint and the knuckle. To avoid damaging the special tools, verify that they are correct for the vehicle you are working on and are aligned properly.
15. Tighten the C-frame and press the lower ball joint out of the knuckle.
Ball Joint Installation
16. Position the new ball joint in the knuckle. Do not remove the boot from the ball joint.
17. Install the special tools on the ball joint and the knuckle.
18. Tighten the C-frame and press the ball joint into the knuckle.
19. 3.5RL and 3.2TL only: Install a new knuckle ring.
20. 2.5TL and CL only Reinstall the brake rotor/hub assembly. Torque the flange bolts to 44 Nm (33 lb-ft). Reinstall the brake caliper. Torque the mounting bolts to 108 Nm (80 lb-ft).
21. Apply wheel bearing grease to the axle splines.
22. Remove the wooden block, then install the axle into the hub. To avoid damaging the ABS sensor harness, do not let the knuckle hang by its weight.
*23. Distribute the grease inside the ball joint by moving the ball joint stud left-and-right and back-and-forth about ten times. Then rotate the stud in a circle several times.*
24. Install the lower control arm onto the ball joint.
25. Install and torque the ball joint castle nut. Install the new cotter pin.
26. Apply oil to the threads and flange of the new spindle nut. Install the new spindle nut; torque it to 245 Nm (181 lb-ft).
27. Stake the spindle nut.
28. Repeat steps 2 through 27 on the other side.
29. Reinstall the front wheels. Tighten the wheel nuts to 108 Nm (80 lb-ft).
30. Lower the vehicle.
31. Center-punch a completion mark above the third character of the engine compartment VIN.
Example of Customer Letter
Disclaimer