Service Procedure
1. Raise the vehicle on a hoist. Remove the front wheels.2. Remove and discard the spindle nut.
Figure 1: Discard the cotter pin and remove the castle nut.
3. Remove the cotter pin and castle nut from the lower ball joint. (Figure 1)
^ Discard the cotter pin.
4. Separate the lower control arm using suitable method.
^ Special tool illustrated in the Workshop Manual is not required.
IMPORTANT
Once separated from the lower arm, do not allow the knuckle assembly to hang by it's own weight, or ABS sensor may become damaged
5. Remove the axle from the front wheel hub.
^ Tap the end of the axle with a rubber mallet to loosen.
Figure 2: Insert a block of wood to keep the assembly up.
6. Lift the knuckle, then place a block of wood (approximately 2-3/4" x 1-1/2" x 5") between the upper control arm and the damper assembly. (Figure 2)
7. Remove (4) brake hose mounting bolts.
^ There are two bolts at the knuckle and two bolts at the damper tube.
Figure 3: Do not allow the caliper to hang freely.
8. Remove the brake caliper mounting bolts and hang the caliper to the radius rod, using appropriate method. (Figure 3)
Figure 4: Remove these bolts, while holding the rotor.
Figure 5: Remove the hub unit and brake rotor.
9. Remove the four flange bolts, and remove the hub unit assembly with brake rotor attached. (Figure 4 and 5)
10. Remove the boot from the lower ball joint.
Figure 6: Arrange adapters to C-Frame Tool.
11. Arrange the special tools for ball joint removal. (Figure 6)
Figure 7: Install adapter (A) to ball joint using castle nut.
12. Install Remover/Installer Adapter (A) to the ball joint with the castle nut. (Figure 7)
13. Clean the recessed area around the ball joint cap and knuckle with solvent and compressed air. To remove remaining debris, a brush may be used. This is necessary to allow proper seating of base remover adapter (F) around the ball joint cap.
IMPORTANT
Incorrect seating (misalignment) of adapter (F) due to foreign debris will result in possible damage to tool during Step 15.
Figure 8: Position the adapters for ball joint removal.
14. Position the special tool onto the lower ball joint and knuckle. (Figure 8)
^ To avoid damaging the special tools, verify that the correct tools are used and aligned properly.
15. Using the C-frame with proper adapters (G, F, A, and H), press the lower ball joint out of the knuckle by tightening the C-frame.
Arrange adapters to C-Frame Tool.
16. Arrange the special tools for ball joint installation. (Figure 9)
17. Position the new ball joint in the knuckle.
Figure 10: Position the adapters for ball joint installation.
18. Position the special tools on the ball joint and the knuckle. (Figure 10)
19. Using the C-frame with proper adapters (E, A, and H), press the lower ball joint into the knuckle by tightening the C-frame.
20. Reinstall the brake rotor and hub unit assembly with the four flange bolts. (Refer to Figures 4 and 5)
^ Torque flange bolts to 44 Nm (33 lb. ft.).
21. Reinstall the brake caliper.
^ Torque the brake caliper mounting bolts to 108 Nm (80 lb. ft.).
22. Reinstall the four brake hose mounting bolts.
^ Torque the two bolts at the knuckle to 9.8 Nm (7 lb. ft.).
^ Torque the two bolts at the damper tube to 22 Nm (16 lb. ft.).
23. Remove the wooden block, and reinstall the axle into the hub.
^ To avoid damaging the ABS sensor harness, do not let the knuckle hang by its weight.
24. Position the new installed lower ball joint into the lower control arm.
25. Install a new ball joint castle nut.
^ Torque the nut to 49-59 Nm (36-43 lb. ft.).
^ Install a new cotter pin to the castle nut.
26. Install a new spindle nut.
^ Apply oil to the threads and flange of the nut before installation.
^ Torque the nut to 245 Nm (181 lb. ft.).
Figure 11: Stake the spindle nut at the notched spindle area.
^ Stake the spindle nut. (Figure 11)
27. Repeat steps 2 through 26 for the other side.
28. Reinstall the front wheels.
^ Torque the wheel nuts to 108 Nm (80 lb. ft.).
29. Lower the vehicle.
30. Fill out and affix a campaign completion label using procedure in the next section.