Service Procedure

1. Raise the vehicle on a hoist and remove both front wheel and tire assemblies.

2. Remove and discard the tie rod nut.





3. Separate the tie rod end from the steering knuckle using special tool C-3894A (Figure 1).

CAUTION:
Do not use a "pickle fork" type tool to separate the tie rod end from the steering knuckle. Tie rod end boot damage may occur.





4. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly (Figure 2).

CAUTION:
Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely.

5. Place a mark on one of the wheel studs and rotor to index the rotor to the hub.

6. Remove and discard the brake rotor retaining clips and then slide the brake rotor off of the axle hub.

7. For vehicles with ABS, remove the wheel speed sensor.

8. For four wheel drive vehicles, remove the axle shaft nut (Figure 1).

9. Remove and discard the lower ball joint nut (Figure 2).





10. Separate the lower ball joint from the lower control arm using special tool C-4150A (Figure 3).

11. Remove and discard the upper ball joint nut.

CAUTION:
Use care so that the upper ball joint boot is not damaged.





12. Separate the upper ball joint from the knuckle using tool C-4150A (Figure 4).

CAUTION:
Do not use a "pickle fork" type tool to separate the upper ball joint from the steering knuckle. Upper ball joint boot damage may occur.

13. Carefully remove the steering knuckle from the vehicle.

14. For vehicles with four wheel drive, move the axle shaft to the side and support the axle shaft.

15. Secure the steering knuckle in a vise.

CAUTION:
Do not over tighten the vise, steering knuckle damage could occur.





16. Remove and discard the lower ball joint boot and boot retaining clip (Figure 5).

CAUTION:
Failure to remove the ball joint boot and retaining clip before pressing the ball joint out of the steering knuckle will make ball joint removal difficult.





17. Press the lower ball joint from the steering knuckle using special tool C-4212F (press), 8859-2 (receiver) and 8859-1 (driver) (Figure 6).

NOTE:
Make sure the receiver is centered over the ball joint before pressing the ball joint from the knuckle.

18. Remove any debris from the ball joint bore located in the steering knuckle.





19. Install the new ball joint into the steering knuckle and press into position using special tools C-4212-F (press), 8859-3 (driver) and 6761 (receiver) (Figure 7).

CAUTION:
The white plastic ball joint boot protective cover must be in place while pressing the new ball joint into the knuckle. The protective cover will prevent boot damage during ball joint installation.

20. Remove and discard the white plastic ball joint boot protective cover from the new ball joint after the ball joint has been pressed into the knuckle.

21. Inspect the ball joint boot for any damage. If a damaged boot is found the joint must be replaced.

22. For vehicles with four wheel drive, remove the support for the front axle shaft and place it into position.

NOTE:
If the threads on the upper ball joint or tie rod end are corroded, use a 14mm x 1.50 thread tap to clean the threads.

23. Remove the steering knuckle from the vise and install the steering knuckle into position.

CAUTION:
The ball joint stud and tapered hole in the control arm must be clean and oil free before installing the steering knuckle into position.

24. Install the supplied new upper ball joint nut. Tighten the nut to 60 ft. lbs. (81 Nm).

25. Install the supplied new lower ball joint nut. Tighten the nut to 60 ft. lbs. (81 Nm).

26. For vehicles with four wheel drive, install the axle shaft nut. Tighten the axle shaft nut to 96 ft. lbs. (130 Nm).

27. For vehicles with ABS brakes, install the wheel speed sensor. Tighten the mounting bolt to 120 in. lbs. (13.5 Nm).

28. Install the disc brake rotor onto the axle hub while aligning the indexing marks made in Step 5.

29. Install the brake caliper adapter (with the caliper) onto the steering knuckle. Tighten the caliper adapter mounting bolts to 100 ft. lbs. (135 Nm) (Figure 2).





30. Connect the tie rod end to the steering knuckle and install the supplied new retaining nut (Figure 8). Tighten the tie rod end retaining nut to 60 ft. lbs. (81 Nm).





31. On 2002 and 2003 model year vehicles, inspect the steering knuckle for the presence of a ball joint heat shield. Vehicles without heat shields must have them installed (Figure 9).

32. Repeat Steps 2 through 31 to replace the ball joint on the other side of the vehicle and then continue with Step 33.

33. Install the right and left side wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs. (135 Nm).

34. Lower the vehicle from the hoist.

35. Pump the brake pedal several times before moving the vehicle.

36. Return the vehicle to the customer.