Steering/Suspension - Replaceable Ball Joints
06-015June 21, 2006
Applies To:
1999-03 3.2 TL - ALL
2001-03 3.2 CL - ALL
Replaceable Ball Joints
BACKGROUND
A replaceable ball joint is now available that allows you to replace only the ball joint and not the entire knuckle assembly. This part is for one-time replacements only.
CORRECTIVE ACTION
Inspect the base of the existing ball joint before beginning repair work. If the ball joint is not stamped with the letter "B", then you can replace only the ball joint. If the letter "B" is stamped on the base, disregard this service bulletin and replace the entire knuckle assembly.
PARTS INFORMATION
Ball Joint: P/N 06523-S84-405
Spindle Nut: P/N 90305-SD4-003
Cotter Pin: P/N 94201-30220
TOOL INFORMATION
Base Installer Adapter: T/N 07XAF-001040A
Base Remover Adapter (C): T/N 07GAF-SD4031A
C-Frame Press: OTC 7248 (order thru normal parts ordering channels)
Pilot Adapter (G): T/N 07XAF-001050A
Remover/Installer Adapter (A): T/N 07GAF-SD40330
Remover/Installer Pilot Adapter (H):
T/N 07XAF-001 020A
Ball Joint Thread Protector: T/N 07AAF-SDAA100
Ball Joint Separator: T/N 07MAC-SL00200
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Failed Part: P/N 51220-584-A02
Defect Code: 00504
Symptom Code: 01201
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
NOTE:
Wear eye protection during the entire procedure.
1. Raise the vehicle on a lift, and inspect the affected ball joint for the letter "B" stamped on the base. If there is a letter "B", disregard this service bulletin and replace the entire knuckle. If "B" is not stamped, remove the front wheels.
2. Remove the old spindle nut.
3. Remove the cotter pin and castle nut from the lower ball joint.
4. Separate the lower control arm from the ball joint with the ball joint separator tool. Do not let the knuckle hang by its own weight or you may damage the ABS sensor harness.
5. Remove the outer CV joint shaft from the front wheel hub. If the shaft is stuck in the hub, go to step 6. If the shaft 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 shaft from the hub. Do not pull it all the way out.
8. Remove the castle nut, then lift and support the knuckle (to prevent damaging the ABS sensor wire harness). Press the shaft all the way 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. Clean the recessed area around the ball joint with solvent and compressed air, then install base remover adapter C.
12. Hold remover/installer adapter 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 and are properly aligned.
13. Tighten the C-Frame, and press the lower ball joint out of the knuckle.
14. Position the new ball joint in the knuckle. Do not remove the boot from the ball joint.
15. Install the special tools on the ball joint and the knuckle.
16. Tighten the C-frame, and press the ball joint into the knuckle.
17. Apply wheel bearing grease to the outer CV joint shaft splines.
18. Remove the wooden block, then install the outer CV joint shaft into the hub. To avoid damaging the ABS sensor harness, do not let the knuckle hang by its own weight.
19. Distribute the grease inside the new ball joint by moving the ball joint stud left to right and back and forth about 10 times. Then rotate the stud in a circle several times.
20. Install the lower control arm to the ball joint.
21. Install the ball joint castle nut. Torque the nut to 49-59 N.m (36-43 lb-ft). Tighten it to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the nut by loosening it. Install the new cotter pin.
22. Apply oil to the threads and flange of the new spindle nut, and torque it to 245 N.m (181 lb-ft).
23. Stake the spindle nut.
24. Repeat steps 2 thru 23 on the other side if necessary.
25. Reinstall the front wheels. Before installing the wheels, clean the mating surface of the brake disc and the inside of the wheel. Torque the wheel nuts to 108 N.m (80 lb-ft).
26. Lower the vehicle.
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