Removal and Installation

Steering Knuckle, Axle Shaft, ABS Speed Sensor:

REMOVAL
1. Remove front axle hub.
Service and Repair

2. Remove ABS speed sensor. Remove the 2 bolts and disconnect the speed sensor from the steering knuckle.





4. Remove dust seal and dust cover. Remove the 8 bolts, dust seal, dust cover and gasket.
4. Remove knuckle spindle.
a. Using a brass bar and hammer, tap the knuckle spindle of the steering knuckle.
b. Remove the knuckle spindle and gasket.

5. Remove axle shaft. Position one flat part of the outer shaft upward and remove the axle shaft.





6. Disconnect tie rod from knuckle arm.
a. Remove the cotter pin and nut.
b. Using SST 09611-22012, disconnect the tie rod from the knuckle arm.





7. Remove oil seal set.
a. Remove the 6 bolts from the end retainer.
b. Remove the oil seal end retainer, felt dust seal, rubber seal and the steel ring from the knuckle.





8. Remove knuckle arm and bearing cap.
a. Remove the 2 bolts and plate washers from the bearing cap.
b. Remove the 4 nuts from the knuckle arm.
c. Using a brass bar and hammer, tap on the 4 bolts heads and remove the 4 cone washers.





d. Using SST 09606-60020, remove the bearing cap and shim from the steering knuckle.

HINT:
^ Use the SST without a collar.
^ In some cases, to satisfy the standard value of preload, more than one shims are used.





e. Using SST 09606-60020, remove the knuckle arm and shim from the steering knuckle.

HINT:
^ Use the SST without a collar.
^ In some cases, to satisfy the standard value of preload, more than one shims are used.

9. Remove steering knuckle and bearing.

HINT: Mark the removed adjusting shim and bearings so as to enable reassembling them to their proper positions.





10. Remove oil seal to axle housing. Using SST 09308-00010, remove the oil seal.

Steering Knuckle, Axle Shaft, ABS Speed Sensor:

INSTALLATION
1. Install oil seal to axle housing. Using SST 09618-60010 and a hammer, install a new oil seal into the axle housing.
2. Install oil seal set. Install the oil seal and retainer, felt dust seal, rubber seal and steel ring to the knuckle.





3. Pack bearings with lithium base wheel bearing grease, NLGI No. 2
a. Place lithium base wheel bearing grease, NLGI No. 2 on your hand.
b. Pack grease into the bearing until the grease oozes out from the outer side.
c. Do the same around the bearing circumference.

4. Install steering knuckle and bearings.
a. Place the bearings in positions on the knuckle and axle housing.
b. Install the knuckle on the axle housing.





5. Install knuckle arm and bearing cap.
a. Using SST 09606-60020, support the upper bearing inner race.

HINT: Use the SST with a collar.

b. Install the bearing cap over the shim that were originally used.
c. Using a hammer, install the bearing cap into the bearing inner race.





d. Using SST 09606-60020, support the lower bearing inner race.

HINT: Use the SST with a collar.

e. Using a hammer, tap the knuckle arm and shim into the bearing inner race.
f. Remove the SST from the knuckle.
g. Install the 4 cone washers and nuts.

Torque: 96 Nm (71 ft. lbs.)

h. Install the 2 plate washers and bolts.

Torque: 96 Nm (71 ft. lbs.)





6. Measure bearings preload. Using a spring tension gauge, measure the preload.

Preload (at starting): 25 - 44 N (5.6 - 9.9 lbs.)

7. Adjust bearing preload.
a. Remove the bearing cap and knuckle arm.
b. Select the adjusting shim. Adjusting shim thickness:

Thickness:
0.1 mm (0.004 inch)
0.2 mm (0.008 inch)
0.5 mm (0.020 inch)
1.0 mm (0.039 inch)

c. Install the bearing cap and knuckle arm.

8. Connect tie rod to knuckle arm. Torque the nut and secure it with a new cotter pin.

Torque: 91 Nm (67 ft. lbs.)

9. Install oil seal end retainer to knuckle arm. Install the oil seal end retainer to steering knuckle with the 6 bolts.

Torque: 5.4 Nm (48 inch lbs.)

10. Install axle shaft. Position one flat part of the outer shaft upward and install the shaft.





11. Pack molybdenum disulfide lithium base grease, NLGI No. 2 into the knuckle to about 3 fourths of the knuckle.
12. Install knuckle spindle, dust cover with gaskets and dust seal.
a. Place a new gasket in the position on the knuckle and install the spindle. Place the dust cover, dust seal and a new gasket on the spindle.
c. Torque the 8 bolts.

Torque: 47 Nm (34 ft. lbs.)

13. Connect ABS speed sensor. Connect the speed sensor and 2 bolts to the steering knuckle.

Torque: 18 Nm (13 ft. lbs.)

14. Install axle hub.
15. Check front wheel alignment.
16. Check ABS speed sensor signal.