Front Steering Knuckle: Service and Repair
REMOVAL - STEERING KNUCKLE1. Raise the vehicle.
NOTE: When removing the center cap from the wheel, do not use a sharp or hard tool. Use of such a tool can mare the finish on the wheel and damage the center cap.
2. Remove the center cap from the wheel. The center cap is removed by inserting a trim stick into the notch on the center cap and prying it off the wheel.
3. Remove the wheel and tire assembly.
4. Remove the 2 bolts attaching the disc brake caliper to the caliper adapter..
5. Remove the disc brake caliper from the caliper adapter. The caliper is removed by first rotating the free end of the caliper away from the caliper adapter. Then, with the free end of the caliper rotated away from the adapter, lift the caliper off the machined abutment on the adapter.
NOTE: The upper control arm on this vehicle has an anodized finish applied to it. When hanging the disc brake caliper from the control arm do not use wire or any similar material that would damage the anodized finish. A plastic tie strap is a suitable method of supporting the disc brake caliper.
6. Support the disc brake caliper firmly by hanging it from the upper control arm using a tie strap. Do not let the flexible brake hose support the weight of the brake caliper as damage to the hose can occur.
7. Remove the brake rotor from the hub and bearing.
8. Remove the 4 bolts mounting the hub and bearing, and the caliper adapter to the steering knuckle, then remove those components.
9. Remove the 3 nuts mounting the fender bracket to the steering knuckle. Remove the fender from the steering knuckle.
10. Remove the nut and washer attaching the outer tie rod end to the steering knuckle. To remove the nut, hold the tie rod end stud from rotating with a socket while loosening and removing the nut with a wrench.
11. Remove the outer tie rod from the steering knuckle using Puller, Special Tool C-3894-A.
NOTE: The lower ball joint to steering knuckle attaching nut is not be reused. Discard the attaching nut after it is removed.
12. Remove the nut and washer from the stud of the upper ball joint.
NOTE: Nut, Special Tool 6998-2, is part of Remover, Special Tool 6998, which is used to remove the upper and lower ball joint stud from the steering knuckle.
13. Install Nut, Special Tool 6998-2, on the stud of the upper ball joint. The nut must be installed so it is fully seated against the steering knuckle, but it does not need to be tightened.
NOTE: The lower ball joint to steering knuckle attaching nut is not to be reused. Discard the attaching nut when it is removed.
14. Remove the nut from the stud of the lower ball joint.
15. Install Remover, Special Tool 6998, between Special Tool 6998-2 and the lower ball joint stud.
CAUTION: Do not strike the steering knuckle or apply heat to the steering knuckle when separating the ball joint stud from the steering knuckle.
16. To release the lower ball joint form the knuckle, first place a wrench on the portion of Special Tool 6998 that is against Special Tool 6998-2 to keep it from rotating. Using another wrench, tighten the threaded end of Remover against the stud of the lower ball joint. This will press the lower ball joint stud out of the steering knuckle. After released from the knuckle, do not completely remove the ball joint stud from the knuckle.
17. Remove the Remover, Special Tool 6998, from the steering knuckle. Remove the Nut, Special Tool 6998-2 from the upper ball joint stud.
NOTE: Nut, Special Tool 6998-1, is part of Remover, Special Tool 6998, which is used to remove the upper and lower ball joint stud from the steering knuckle.
18. Install Nut, Special Tool 6998-1, on the lower ball joint stud, which is still loosely in knuckle lower ball joint hole, until the nut is on far enough to contact knuckle. Do not tighten the nut on the lower ball joint stud.
19. Install Remover, Special Tool 6998, between Special Tool 6998-1 and the upper ball joint stud.
CAUTION: Do not strike the steering knuckle or apply heat to the steering knuckle, when separating the ball joint stud from the steering knuckle.
20. Using a wrench, keep the section of special tool 6998 that is against Special Tool 6998-1 from rotating. Tighten the threaded end of Remover, Special Tool 6998, against the stud of the upper ball joint. This will press the lower ball joint stud out of the steering knuckle.
21. Remove the Remover, Special Tool 6998, from the steering knuckle. Remove the Nut, Special Tool 6998-1, from the lower ball joint stud.
22. Remove the steering knuckle from the control arm ball joints.
INSTALLATION - STEERING KNUCKLE
1. Install the steering knuckle on the studs of the upper and lower ball joints.
CAUTION: When installing the lower ball joint on the steering knuckle a new mounting nut MUST be used. This is required to provide for the proper tightening and torque retention of the ball joint attaching nut.
NOTE: The lower ball joint nut has a plastic skirt attached to the bottom of it. The skirt is used to pull the stud of the ball joint into the steering knuckle as the nut is tightened. This prevents the stud from rotating in the steering knuckle allowing the nut to be properly torqued.
2. Install a NEW lower ball joint to steering knuckle attaching nut, but do not fully tighten it at this time.
CAUTION: To ensure the stud of the upper ball joint is adequately pulled into the steering knuckle, the original style nut and washer must be installed.
3. Install the nut and washer on the stud of the upper ball joint, but do not fully tighten it at this time.
4. Install outer tie rod end on steering knuckle.
CAUTION: To ensure the stud of the tie rod end is adequately pulled into the steering knuckle, the original style nut and washer must be installed.
5. Install the outer tie rod to steering knuckle attaching nut and washer. Tighten the tie rod attaching nut to a torque of 52 Nm (38 ft. lbs.) using a crow foot and a socket on the stud.
6. Tighten the lower ball joint stud attaching nut. As the new ball joint nut is tightened, the skirt will fold upward. Continue to tighten the nut until a torque of 95 Nm (70 ft. lbs.) is reached.
7. Tighten the upper ball joint stud attaching nut to a torque of 129 Nm (95 ft. lbs.).
8. Install the brake caliper adapter and the hub and bearing on the steering knuckle.
9. Install the 4 bolts mounting the caliper adapter and the hub and bearing to the steering knuckle. Tighten the 4 bolts to a torque of 60 Nm (45 ft. lbs.).
10. Install the front fender and bracket on the steering knuckle. Install the 3 nuts mounting the fender bracket to the steering knuckle. Tighten the 3 nuts to a torque of 41 Nm (30 ft. lbs.).
11. Install the brake rotor on hub and bearing.
12. Install the disc brake caliper on the caliper adapter, reversing the removal procedure.
13. Install the brake caliper guide pin bolts. Tighten the bolts to a torque of 27 Nm (20 ft. lbs.).
14. Install the wheel and tire assembly.
15. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
16. Install the center cap on the wheel.
17. Lower the vehicle.
18. Position the vehicle correctly on an alignment rack.
19. Check and adjust the alignment to meet the preferred alignment specifications for this vehicle.