Service Procedure Maintenance-Free Ball Joint Replacement
SERVICE PROCEDURE MAINTENANCE-FREE BALL JOINT REPLACEMENT, UPPER & LOWER:
1988-89 C TRUCK
Required Tools:
J 23742 Ball Joint Separator
J 9519-D Ball Joint Remover and Installer Set
J 24319-01 Steering Linkage Puller
- Raise vehicle and support it with safety jack stands.
- Support lower control arm with a jack and secure spring with a safety chain.
CAUTION: Jack or stand must remain under the lower control arm spring seat during removal and Installation to retain the spring and control arm in position.
Figure 2 - Control Arms and Components:
Remove (figure 2)
1. Wheel and tire assembly.
2. Brake line support (86) from upper control arm (42).
3. Brake caliper and rotor.
Figure 3 - Disconnecting the Ball Joint:
Important
Support the caliper with a piece of wire to prevent damage to the brake line.
4. Cotter pin (68) and stud nut (67) from the upper ball joint (66).
5. Upper ball joint (66) from knuckle.
- Support the knuckle assembly.
- Use J 23742 as shown in figure 3.
- Inspect the tapered hole in the knuckle and remove any dirt. If the hole is out of round, deformed or damaged, the knuckle must be replaced.
Figure 4 - Drilling the Ball Joint Rivets:
6. Rivets from upper ball joint (66).
- If ball joint has been previously replaced, remove bolts and skip to step 7.
- Center punch the top of the rivets.
- 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 (figure 4).
Figure 5 - Drilling the Ball Joint Rivet Heads:
- Drill the rivet heads away using a 12.7 mm (1/2-inch) drill (figure 5).
Figure 6 - Removing the Ball Joint Rivets:
- Punch the rivets out using a punch (figure 6).
7. Upper ball joint (66).
Figure 7 - Installing the Upper Ball Joint:
Install (figure 7)
1. New upper ball joint (66) to the upper control arm (42).
- Position four attaching bolts pointing upward, washers and nuts
- Tighten nuts (A) to 23 N-m (17 lbs.ft.).
Figure 2 - Control Arms and Components:
Remove (figure 2)
1. Cotter pin (68) and stud nut (67) from the lower ball joint (69).
2. Lower ball joint (69) from knuckle.
- Support the knuckle assembly.
- Use J 24319-01 to break the ball joint loose from the knuckle.
- Inspect the tapered hole in the knuckle and remove any dirt. If the hole is out of round, deformed or damaged, the knuckle must be replaced.
- Move knuckle assembly aside and support.
3. Lower ball joint (69) from the lower control arm (40).
Figure 8 - Removing the Lower Ball Joint:
- Use tools as shown in figure 8.
Figure 2 - Control Arms and Components:
Install (figure 2)
1. New lower ball joint (69) to the lower control arm (40).
Figure 9 - Installing the Lower Ball Joint:
- Press in the ball joint using tools in figure
9. The ball joint will bottom on the control arm.
2. New lower ball joint (69) to the knuckle.
3. Lower stud nut (67) and new cotter pin (68).
- Tighten stud nut (67) to 128 N-m (94 lbs.ft.).
- Align the slot in the stud nut with the hole in the stud by tightening the stud nut.
- Bend the pin ends against the nut.
4. New upper ball joint (66) to the knuckle.
5. Upper stud nut (67) and new cotter pin (68).
- Tighten stud nut (67) to 100 N-m (75 lbs.ft.).
- Align the slot in the stud nut with the hole in the stud by tightening the stud nut.
- Bend the pin ends against the stud nut.
6. Brake rotor and caliper.
7. Brake line support (86) to upper control arm (42).
8. Wheel and tire assembly.
9. Repeat above procedure on opposite side of vehicle.
MAINTENANCE-FREE BALL JOINT REPLACEMENT, UPPER ONLY: 1990 C TRUCK
Required Tools:
J 23742 Ball Joint Separator
- Raise vehicle and support it with safety jack stands.
- Support lower control arm with a jack and secure spring with a safety chain.
CAUTION: Jack or stand must remain under the lower control arm spring seat during removal and Installation to retain the spring and control arm in position.
Remove (figure 2)
1. Wheel and tire assembly.
2. Brake line support (86) from upper control arm (42).
3. Brake caliper and rotor.
Important
Support the caliper with a piece of wire to prevent damage to the brake line.
4. Cotter pin (68) and stud nut (67) from the upper ball joint (66).
5. Upper ball joint (66) from knuckle.
- Support the knuckle assembly.
Figure 3 - Disconnecting the Ball Joint:
- Use J 23742 as shown in figure 3.
- Inspect the tapered hole in the knuckle and remove any dirt. If the hole is out of round, deformed or damaged, the knuckle must be replaced.
6. Rivets from upper ball joint (66).
- If ball joint has been previously replaced, remove bolts and skip to step 7.
- Center punch the top of the rivets.
Figure 4 - Drilling the Ball Joint Rivets:
- 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 (figure 4).
Figure 5 - Drilling the Ball Joint Rivet Heads:
- Drill the rivet heads away using a 12.7 mm (1/2-inch) drill (figure 5).
Figure 6 - Removing the Ball Joint Rivets:
- Punch the rivets out using a punch (figure 6).
7. Upper ball joint (66).
Figure 2 - Control Arms and Components:
Install (figure 2)
1. New upper ball joint (66) to the upper control arm (42).
Figure 7 - Installing the Upper Ball Joint:
- Position four attaching bolts pointing upward, washers and nuts (figure 7).
- Tighten nuts (A) to 23 N-m (17 lbs.ft.).
2. New upper ball joint (66) to the knuckle.
3. Upper stud nut (67) and new cotter pin (68).
- Tighten stud nut (67) to 100 N-m (75 lbs.ft.).
- Align the slot in the stud nut with the hole in the stud by tightening the stud nut.
- Bend the pin ends against the stud nut.
4. Brake rotor and caliper.
5. Brake line support (86) to upper control arm (42).
6. Wheel and tire assembly.
7. Repeat above procedure on opposite side of vehicle.
MAINTENANCE-FREE BALL JOINT REPLACEMENT, UPPER & LOWER:
1988-90 K TRUCK
Required Tools:
J 36607 Ball Joint Separator
J 24319-01 Steering Linkage Puller
Raise vehicle and support it with safety jack stands.
Support lower control arm with a jack.
CAUTION: Jack or stand must remain under the lower control arm spring seat during removal and installation to retain the torsion bar and control arm in position.
Figure 10 - Hub. Knuckle and the Ball Joints:
Remove (figure 10)
1. Wheel and tire assembly.
2. Brake caliper and rotor.
Important
Support the caliper with a piece of wire to prevent damage to the brake line.
3. Cotter pin (130) and stud nut (129) from the upper ball joint (115).
4. Upper ball joint (115) from knuckle (117).
- Support the knuckle assembly.
Figure 11 - Disconnecting the Ball Joint:
- Use J 36607 as shown in figure 11.
- Inspect the tapered hole in the knuckle and remove any dirt. If the hole is out of round, deformed or damaged, the knuckle must be replaced.
5. Rivets from upper ball joint (115).
- If ball joint has been previously replaced, remove bolts and upper ball joint and skip to step 7.
- Center punch the top of the rivets.
Figure 4 - Drilling the Ball Joint Rivets:
- Use a 4.763 mm (3/16-inch) drill to cut a
4. 6.35 mm (1/4-inch) deep hole in the center of each rivet (figure 4).
Figure 5 - Drilling the Ball Joint Rivet Heads:
- Drill the rivet heads away using a 12.7 mm (1/2-inch) drill (figure 5).
6. Upper ball joint (115) from the upper control arm (101). Rivets will remain in control arm.
Important
Do not damage the upper control arm mounting surface when removing the ball joint or rivets. Remove remaining rivet shanks flush with control arm.
Figure 6 - Removing the Ball Joint Rivets:
- Support the upper control arm and punch the rivets out using a punch (figure 6).
Figure 12 - Installing the Upper Ball Joint:
Install (figure 12)
1. New upper ball joint (115) to the upper control arm (101) (C truck arm shown, K truck arm typical).
- Position four attaching bolts pointing upward, washers and nuts.
- Tighten nuts (A) to 23 N-m (17 lbs.ft.).
Figure 10 - Hub. Knuckle and the Ball Joints:
Remove (figure 10)
1. Drive axle shaft nut (120) and washer (119) from the hub assembly (114).
2. Cotter pin (130) and stud nut (131) from the
lower ball joint (127).
3. Lower ball joint (127) from the knuckle (117).
- Support the knuckle assembly.
- Use J 24319-01.
- Drive axle must be removed from hub assembly at the same time.
- Move knuckle aside and support.
- Move drive axle aside and support.
- Inspect the tapered hole in the knuckle and remove any dirt. If the hole is out of round, deformed or damaged, the knuckle must be replaced.
4. Rivets from lower ball joint (127). (Figure 13)
- If ball joint has been previously replaced, remove bolts and skip to step 5.
- Center punch the top of the rivets.
Figure 4 - Drilling the Ball Joint Rivets:
- Use a 4.763 mm (3/16-inch) drill to drill through the center of each rivet (figure 4).
- Use a 7.938 mm (5/16-inch) drill to enlarge the hole through the center of each rivet.
Figure 5 - Drilling the Ball Joint Rivet Heads:
- Drill rivet heads away using a 12.7 mm (1/2-inch) drill (figure 5).
Important
Use caution to avoid drilling through rivet head and into lower control arm.
- Use a chisel and hammer to remove any remaining rivet head.
- Punch out the rivets using a punch (figure 6).
5. Lower ball joint (127) from the lower control arm (93).