Front Steering Knuckle: Service and Repair

NOTE: Before proceeding, review all SERVICE WARNINGS AND CAUTIONS found under Suspension, Service Precautions.

REMOVAL
1. Raise vehicle. See Maintenance for the required lifting procedure.
2. Remove front wheel and tire assemblies.






3. Remove the attaching bolt for the front hub/ bearing used to mount the brake hose bracket to the steering knuckle.






4. Remove the 2 bolts attaching the brake caliper to the steering knuckle. Remove the brake caliper from the steering knuckle.






5. Support brake caliper by hanging it from the upper control arm with mechanics wire. Do not let brake caliper hang by brake flex hose.
6. Remove the brake rotor from the hub/bearing.






7. Remove the cotter pin and attaching nut from the outer tie rod end.






8. Remove the outer tie rod from the steering knuckle using Puller, Special Tool C-3894-A.






9. Remove the cotter pin and nut from the stud of the lower ball joint.






NOTE: When installing the Spacer, Special Tool 6983, between the grease seal and steering knuckle, it must be installed in the direction as shown.

10. Install Spacer, Special Tool 6983, between the lower ball joint grease seal and the steering knuckle.

CAUTION: Do not strike the steering knuckle or apply heat to the steering knuckle when separating the ball joint stud from the steering knuckle.











11. Install Puller, Special Tool C-4150A, on steering knuckle. The ball bearing in the bolt of Special Tool C-4150A must be centered in the stud of the lower ball joint. Also, the Spacer, Special Tool 6983, must be installed between the steering knuckle and Special Tool C-4150-A, as shown.






12. Remove the cotter pin and nut attaching the upper ball joint stud to the steering knuckle.

CAUTION: Do not strike the steering knuckle or apply heat to the steering knuckle, when separating the ball joint stud from the steering knuckle.







13. Remove the upper ball joint stud from the steering knuckle using Remover, Special Tool C-4150A.
14. Remove the steering knuckle from the upper, and lower control arm.
15. Transfer the front hub/bearing to the replacement steering knuckle.

INSTALLATION
1. Install the steering knuckle on the stud of the lower ball joint. Loosely install the attaching nut on the ball joint.
2. Install the steering knuckle on the stud of the upper ball joint. Loosely install the attaching nut on the ball joint.
3. Install outer tie rod onto steering knuckle. Install tie rod to steering knuckle attaching nut. Tighten the tie rod attaching nut to a torque of 34 Nm (25 ft. lbs.). Install the cotter pin in stud of tie rod end.
4. Tighten the upper ball joint stud attaching nut to a torque of 102 Nm (75 ft. lbs.). After tightening nut to specified torque, continue to tighten until cotter pin can be installed through nut and hole in ball joint stud (DO NOT LOOSEN NUT).
5. Install cotter pin through nut and stud of upper ball joint.
6. Tighten the lower ball joint stud attaching nut to a torque of 160 Nm (118 ft. lbs.). After tightening nut to specified torque, continue to tighten until cotter pin can be installed through nut and hole in ball joint stud (DO NOT LOOSEN NUT).
7. Install cotter pin through nut and stud of lower ball joint.
8. Install the brake rotor on front hub/bearing.
9. Install the brake caliper on the steering knuckle.
10. Install the brake caliper attaching bolts and tighten to a torque of 115 Nm (85 ft. lbs.).
11. Align the brake hose bracket with the hole in steering knuckle. Install the mounting bolt for the hub/bearing. Tighten the hub/bearing mounting bolt to a torque of 61 Nm (45 ft. lbs.).
12. Install the wheel and tire. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 122 Nm (90 ft. lbs.).
13. Lower the vehicle.
14. Position vehicle on an alignment rack or drive-on hoist.
15. Measure the vehicle's curb height and correct as necessary. Refer to Curb Height Measurement found in Wheels, Tires and Alignment, Alignment, Adjustments.
16. Align the vehicle per the service procedure listed in Wheel Alignment.