Service Procedure

FIGURE NO. 1 - STEERING LINKAGE:

FIGURE NO. 3 - STEERING LINKAGE - K MODEL:

Inspect tie rod outer ball joint nuts, Figure No. 1 & 3 Item 1, for crimp marks. A properly torqued nut will have small indentations on the flat sides of the nut. Check both sides of the vehicle. If there are crimp marks in the nuts no further action is required. The nuts were properly torqued in production. If there are no crimp marks in the nuts, the nuts are loose. In this case the outer tie rods and steering knuckles must be replaced. The service procedure for replacement of these parts is listed below.

FIGURE NO. 1 - STEERING LINKAGE:

FIGURE NO. 2 - HUB,KNUCKLE AND BEARING COMPONENTS:

2-WHEEL DRIVE

Refer to Figure No. 1 & 2 and Section 3, steering, suspension, wheels and tires, and 5, brakes of Service Manual X-8731.

^ Siphon 2/3 of the brake fluid from the master cylinder.

^ Lift and support vehicle.

^ Remove the tire and wheel assembly.

^ Remove the brake caliper from the hub/disc. Suspend the caliper assembly with a wire hook away from the work area.

^ Remove the wheel bearing cap, nut, and washer from the spindle.

^ Remove the hub/disc. Care should be used so that the outer bearing is not damaged. Save the inner and outer bearing cone and rollers.

^ Remove the splash shield and gasket.

^ Remove tie rod ball stud from the knuckle using tool J24319-01. Discard nut.

^ Remove the other end of the tie rod from the adjuster tube. Discard the tie rod. Save the clamp and nut.

^ Remove and discard the inner wheel bearing seal.

^ Remove the upper and lower ball studs from knuckle. Use tool J36607.

FLOOR JACK MUST REMAIN UNDER CONTROL ARM SPRING SEAT DURING REMOVAL AND INSTALLATION TO RETAIN THE SPRING AND CONTROL ARM IN POSITION.

^ Position a floor jack under the lower control arm near the spring seat. Raise the jack until it just supports the lower control arm.

^ Remove and discard the knuckle.

^ Install new knuckle. Torque upper ball joint nut to 90 N-m (66 lb.ft), and the lower ball joint nut to 128 N-m (94 lb.ft). Tighten the nuts to align the cotter pins. Do not tighten more than 1/6 turn. Install new cotter pins.

^ Reinstall splash shield gasket.

^ Reinstall splash shield. Torque bolts to 16 N-m (12 lb.ft).

^ Install new outer tie rod to the adjuster tube. The number of threads on both the inner and outer rod ends must be within three threads. The clamp and bolt should be positioned as shown in Figure No. 1.

^ Seat the tie rod ball stud in the knuckle using tool J29193. Torque nut to 54 N-m (40 lb.ft).

^ Reinstall hub/disc to the spindle using a new inner wheel bearing seal. Refer to hub, bearing & seal replacement, section 3C-11 of the service manual.

^ Apply grease to the outboard side of the outer bearing. Reinstall nut and washer to the spindle. Tighten nut to 16 N-m (12 lb.ft) while turning the hub/disc forward by hand. Adjust the nut to a "just loose" position by hand, then back the nut off until the hole in the spindle aligns with a slot in the nut. Do not back the nut off more than 1/2 flat. Install new cotter pin.

^ Reinstall cap to the hub/disc.

^ Reinstall brake caliper. Torque caliper mounting bolts to 38 N-m (28 lb.ft).

^ Reinstall wheel and tire assembly. Torque nuts to 123 N-m (90 lb.ft).
^ Repeat required steps to replace outer tie rod and knuckle on opposite side of truck, if required.

^ Lube tie rod ball studs with chassis lubricant part number 1052497 or equivalent.

^ Lower vehicle.

^ Refill master cylinder with Delco Supreme II, part number 1052535, or Dot 3 brake fluid and bleed-brake system if required.

FIGURE NO. 5:

^ Readjust the toe-in. Refer to Figure No. 5 for specifications. Torque clamp nut at rod adjuster tube to 20 N-m (15 ft.lbs.).

FIGURE NO. 3 - STEERING LINKAGE - K MODEL:

FIGURE NO. 4 - HUB, KNUCKLE AND THE BALL JOINTS:

4-WHEEL DRIVE

Refer to Figure No. 3 & 4 and Service Manual X-8731, Sections 3 & 5.

^ Siphon 2/3 of the brake fluid from the master cylinder..

^ Lift and support vehicle.

^ Remove the tire and wheel assembly.

^ Remove the brake caliper from the disc. Suspend the caliper assembly with a wire hook away from the work area.

^ Remove the brake disc.

^ Remove the nut and washer from the axle shaft.

^ Remove the six bolts attaching the axle shaft to the differential.

^ Using an appropriate puller push the axle shaft back into the hub to free the shaft.

^ Remove the hub and bearing assembly.

^ Remove the splash shield and gasket from the knuckle.

^ Remove tie rod ball stud from the knuckle. Use tool J24319-01.

^ Remove the other end of the tie rod from the adjuster tube. Discard the tie rod. Save the clamp and nut.

^ Remove and retain the knuckle seal.

^ Remove the upper and lower ball studs from the knuckle. Use tool J36607.

FLOOR JACK MUST REMAIN UNDER THE LOWER CONTROL ARM DURING REMOVAL AND INSTALLATION OF THE KNUCKLE.

^ Position a floor jack under the lower control arm. Raise the jack until it just supports the
lower control arm.

^ Remove and discard the knuckle.

^ Install new knuckle. Torque upper ball joint nut to 90 N-m (66 ft.lbs.), and the lower ball
joint nut to 128 N-m (94 ft.lbs.). Tighten the nuts to align the cotter pins. Do not tighten more than 1/6 turn. Install new cotter pins.

^ Reinstall axle shaft bolts to the differential. Torque bolts to 80 N-m (59 ft.lbs.).

^ Reinstall knuckle seal.

^ Reinstall splash shield, Torque bolts to 16 N-m (12 ft.lbs.).

^ Install new outer tie rod to the adjuster tube. The number of threads on both the inner and outer rod ends must be within three threads. The clamp and bolt should be positioned as shown in Figure No. 3.

^ Seat the tie rod ball stud in the knuckle using tool J29193. Torque nut to 54 N-m (40 ft.lbs.).

^ Reinstall hub and bearing assembly. Tighten bolts to 90 N-m (66 ft.lbs.).

^ Install washer and nut on axle shaft. Tighten nut to 235 N-m (173 ft.lbs.).

^ Reinstall brake disc and caliper. Tighten caliper mounting bracket bolts to 38 N-m (28 ft.lbs.).

^ Reinstall wheel and tire assembly. Torque nuts to 123 N-m (90 ft.lbs.).

^ Repeat required steps to replace outer tie rod and knuckle on opposite side of truck, if required.

^ Lube tie rod ball studs with chassis lube part number 1052497 or equivalent.

^ Lower vehicle.

^ Refill master cylinder with Delco Supreme II, part number 1052535, or Dot 3 brake fluid and bleed brake system if required.

FIGURE NO. 5:

^ Readjust the toe-in alignment. Refer to Figure No. 5 for specifications. Torque clamp nut at tie rod adjuster tube to 20 N-m (15 ft.lbs.).