1988-1990 K Truck Ball Point Replacement

Figure 14:

BALL JOINT REPLACEMENT, UPPER & LOWER: 1988-1990 K TRUCK

Required Tools: J-36607 Ball Joint Separator
J-24319-01 Steering Linkage Puller

1. Raise vehicle and support it with safety jack stands.

2. Support lower control arm with jack.

NOTICE: Jack or stand must remain under lower control arm during removal and installation to retain torsion bar and control arm in position.

3. Remove wheel and tire assembly.

4. Remove brake caliper and rotor.

NOTICE: Support caliper with a piece of wire to prevent damage to brake line.

Figure 10:

5. Remove cotter pin (Fig. 10, 130) and stud nut (Fig. 10, 129) from upper ball joint (Fig. 10, 115).

6. Remove upper ball joint (Fig. 10, 115) from knuckle (Fig. 10, 117)

a. Support knuckle assembly.

Figure 11:

b. Use J-36607 as shown in Figure 11.

c. Inspect tapered hole in knuckle and remove any dirt. If hole is out of round, deformed or damaged, knuckle must be replaced.

Figure 10:

7. Remove rivets from upper ball joint (Fig. 10, 115). If ball joint has been previously replaced, remove bolts and upper ball joint, and skip to step 9.

a. Center punch top of rivets.

Figure 4:

b. Use a 4.763 mm (3/16-inch) drill to cut a 6.35 mm (1/4-inch) deep hole in the center of each rivet (Fig. 4).

Figure 5:

c. Drill rivet heads away using a 12.7 mm (1/2-inch) drill (Fig. 5).

Figure 10:

BALL JOINT REPLACEMENT, UPPER & LOWER: 1988-1990 K TRUCK (Con't)

8. Remove upper ball joint (Fig. 10, 115) from upper control arm (Fig. 10, 101). Rivets will remain in control arm.

NOTICE: Do not damage upper control arm mounting surface when removlng ball joint or rivets.

a. Remove remaining rivet shanks flush with control arm.

Figure 6:

b. Support upper control arm and punch rivets out using a punch (Fig. 6).

Figure 12:

9. Install new upper ball joint (Fig. 12, 115) to upper control arm (Fig. 12, 101 - C Truck arm shown, K Truck arm typical).

a. Position four (4) attaching bolts (pointing upward), washers and nuts.

b. Tighten nuts (A) to 23 N-m (17 lb.ft.).

Figure 10:

10. Remove drive axle shaft nut (Fig. 10, 120) and washer (Fig. 10, 119) from hub assembly (Fig 10, 114).

11. Remove cotter pin (Fig. 10, 130) and stud nut (Fig. 10, 131) from lower ball joint (Fig. 10, 127).

12. Remove lower ball joint (Fig. 10, 127) from knuckle (Fig. 10, 117).

a. Support knuckle assembly.

b. Use J-24319-01.

c. Remove drive axle from hub assembly at same time.

d. Move knuckle assembly aside and support.

e. Move drive axle aside and support.

f. Inspect tapered hole in steering knuckle and remove any dirt. If hole is out of round, deformed or damaged, knuckle must be replaced.

13. Remove rivets from lower ball joint (Fig. 10, 127). If ball joint has been previously replaced remove bolts and skip to step 14.

a. Center punch top of rivets.

Figure 4:

b. Use a 4.763 mm (3/16-inch) drill to drill through center of each rivet (Figure 4).

c. Use a 7.938 mm (5/16-inch) drill to enlarge hole through the center of each rivet.

Figure 5:

d. Drill rivet heads away using a 12.7 mm (1/2-inch) drill (Figure 5).

NOTICE: Use caution to avoid drilling through rivet head and into lower control arm.

e. Use a chisel and hammer to remove any remaining rivet head.

Figure 6:

f. Punch rivets out using a small pin punch (Figure 6).

Figure 10:

Figure 13:

14. Remove lower ball joint (Fig. 10, 127) from lower control arm (Fig. 10, 93).

15. Install new lower ball joint (Fig. 10, 127) to lower control arm (Fig. 13, 93).

a. Ball joint is installed between flanges of the lower control arm.

b. Position four (4) attaching bolts (pointing downward), washers and nuts.

c. Tighten nuts (B) to 60 N-m (45 lb.ft.).

16. Install new lower ball joint (Fig. 10, 127) to knuckle (Fig. 10, 117). Drive axle should be installed through hub assembly at same time.

17. Install stud nut (Fig. 10, 131) and new cotter pin (Fig. 10, 130).

a. Tighten stud nut to 128 N-m (94 lb.ft.).

b. Align slot in stud nut with hole in stud.

c. Bend cotter pin ends against nut.

18. Install upper ball joint (Fig. 10, 115) to knuckle (Fig. 10, 117).

19. Install stud nut (Fig. 10, 129) and new cotter pin (Fig. 10, 130).

a. Tighten stud nut (Fig. 10, 129) to 100 N-m (75 lb.ft.).

b. Align slot in stud nut with hole in stud.

c. Bend cotter pin ends against nut.

20. Install washer (Fig. 10, 119) and drive axle nut (Fig. 10, 120). Tighten nut to 235 N-m (173 lb. ft.).

21. Install brake rotor and caliper.

22. Install wheel and tire assembly.

23. Repeat procedure on opposite side of vehicle.