Front Steering Knuckle: Service and Repair

REMOVAL





1. Loosen the wheel nuts slightly.
2. Raise the front of vehicle, and support it with safety stands in the proper locations.
3. Remove the wheel nuts and front wheel.
4. Raise the locking tab on the spindle nut, then remove the nut.





5. Remove the brake hose mounting bolts.
6. Remove the caliper bracket mounting bolts, and hang the caliper to one side.

CAUTION: To prevent accidental damage to the caliper or brake hose, use a short piece of wire to hang the caliper from the undercarriage.





7. Remove the 6 mm brake disc retaining screws.
8. Screw the two 8 x 1.25 mm bolts into the disc to push it away from the hub.

NOTE: Turn each bolt two turns at a time to prevent cocking the disc excessively.

9. Remove the brake disc from the knuckle.
10. Check the front hub for damage and cracks.





11. Remove the wheel sensor wire bracket, then remove the wheel sensor from the knuckle (with ABS).

NOTE:
- Do not disconnect the wheel sensor connector.
- Use the special tool to separate the ball joints from the suspension or tie-rod end.

CAUTION: Be careful not to damage the ball joint boot.

12. Clean any dirt or grease off the ball joint.
13. Remove the cotter pin from the tie-rod end ball joint 10 mm nut, and loosen the nut.





14. Apply grease to the special tool on the areas shown. This will ease installation of the tool and prevent damage to the pressure bolt threads.





15. Install the special tool as shown. Insert the jaws carefully, making sure you do not damage the ball joint boot.
16. Adjust the jaw spacing by turning the pressure bolt.

NOTE: If necessary, apply penetrating type lubricant to loosen the ball joint.





17. Once the special tool is in place, turn the adjusting bolt as necessary to make the jaws parallel. Then hand-tighten the pressure bolt, and recheck the jaws to make sure they are still parallel.

NOTE: After making the adjustment to the adjusting bolt, be sure the head of the adjusting bolt is in this position to the allow the jaw to pivot.

18. With a wrench, tighten the pressure bolt until the ball joint shift pops loose from the steering arm.

WARNING: Wear eye protection. The ball joint can break loose suddenly and scatter dirt or other debris in your eyes.

19. Remove the special tool, then remove the nut from the end of the ball joint and pull the ball joint out of the steering/suspension arm. Inspect the ball joint boot and replace it if damaged.





20. Remove the cotter pin from the lower arm ball joint castle nut, and remove the nut.
21. Install a 12 mm hex nut on the ball joint. Be sure that the hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damaged by the ball joint remover.
22. Use the special tool as shown to separate the ball joint and lower arm.

NOTE: If necessary, apply penetrating type lubricant to loosen the ball joint.





23. Remove the cotter pin from the upper ball joint castle nut, and remove the nut.
24. Install the 12 mm hex nut on the ball joint.
Be sure that the hex nut is flush with the ball joint pin end, or the threaded section of the ball joint pin might be damaged by the ball joint remover.
25. Use the special tool as shown to separate the ball joint and knuckle.

NOTE: If necessary, apply penetrating type lubricant to loosen the ball joint.





26. Pull the knuckle outward, and remove the driveshaft outboard joint from the knuckle by tapping the driveshaft end with a plastic hammer, then remove the knuckle.

INSTALLATION





1. Install the knuckle on the driveshaft outboard joint.
2. Install the knuckle on the tie-rod end, upper arm and lower arm, then tighten the castle nuts and install the new cotter pins.

CAUTION: Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.





3. Install the wheel sensor with the sensor mounting bolts (with ABS).
4. Install the wheel sensor wire bracket with the two flange bolts (with ABS).

NOTE: Be careful when installing the sensors to avoid twisting wires.





5. Install the brake disc with the 6 mm brake disc retaining screws.

NOTE: Before installing the brake disc, clean the mating surfaces of the front hub and the brake disc.





6. Install the caliper with the caliper bracket mounting bolts.
7. Install the brake hose bracket with the brake hose mounting bolts.

CAUTION: Be careful not to twist the hose more than necessary.





8. Install a new spindle nut, then tighten and stake the nut.
9. Install the wheel with the wheel nuts.

NOTE: Before installing the wheel, clean the mating surfaces of the brake disc and the wheel.

10. Check the front wheel alignment, and adjust if necessary.