B. Replace Right Steering Knuckle

NOTE:
Only cavity "2" steering knuckles, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require steering knuckle replacement.

1. Remove the right front wheel and tire assembly.

2. With the brakes applied, loosen the right front hub nut, then release the brakes.

CAUTION:
Wheel bearing damage will result if the hub nut is loosened and then the vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.

3. Using a C-clamp, slightly compress the caliper piston into the bore.





4. Remove the two (2) bolts that secure the disc brake caliper adapter to the steering knuckle (Figure 2).

5. Remove the disc brake caliper and adapter from the knuckle as an assembly. Hang the caliper assembly out of the way using a wire or bungee cord.

CAUTION:
Do not allow the brake caliper to hang by the brake hose as this may damage the hose.

6. Remove the clips that secure the brake rotor to the wheel studs.

7. Mark the brake rotor position in relation to one of the wheel studs and then remove the brake rotor.





8. Remove the nut that attaches the outer tie rod to the steering knuckle (Figure 3). Remove the nut by holding the tie rod stud with a socket while loosening and removing the nut with a wrench.

9. Remove the tie rod end from the steering knuckle using Special Tool C-3894-A.





10. Remove the ABS wheel speed sensor wire routing bracket from the steering knuckle, if equipped (Figure 4).

11. Remove the ABS wheel speed sensor from the steering knuckle, if equipped.

12. Remove the lower ball joint heat shield from the steering knuckle.





13. Remove the cotter pin and castle nut from the lower ball joint stud (Figure 5).





14. Turn the steering knuckle so that the front is facing as far outboard as possible. Using a hammer, strike the boss on the steering knuckle until the knuckle separates from the lower ball joint stud (Figure 6).

CAUTION:
Do NOT insert any tool between the steering knuckle and the lower ball joint to separate them.

15. Remove the nut from the upper balljoint stud.





16. Remove the upper ball joint stud from the steering knuckle using Special Tool C-3894-A (Figure 7).

17. Lift up on the steering knuckle to separate it from the lower ball joint stud. Use caution so that the ball joint seal does not get cut.

18. Prepare to hang the drive shaft by wrapping a wire or bungee cord around it so that the C/V joint is not damaged when the shaft is separated from the hub.





19. Separate the steering knuckle from the outer C/V joint. Hold the driveshaft in place while pulling the steering knuckle away from the outer C/V joint (Figure 8).

20. Remove the steering knuckle from the vehicle.





21. Remove the three (3) bolts that attach the hub and bearing assembly to the steering knuckle (Figure 9).

22. Remove the hub and bearing assembly from the steering knuckle. Tap the hub and bearing assembly with a soft-faced hammer to remove it if necessary. Discard the knuckle (Figure 9).

23. Install the original hub and bearing assembly into the provided steering knuckle (Figure 9). Align the hub bolt holes with the holes in the steering knuckle.

24. Install the three (3) hub and bearing attaching bolts. Evenly tighten the bolts to ensure that the bearing is square to the face of the steering knuckle. Tighten the bolts to 80 ft-lbs (110 N.m).

25. Slide the driveshaft into the front hub/bearing as the new steering knuckle assembly is installed onto the lower ball joint stud (Figure 8).

26. Install the new lower ball joint castle nut but do not tighten.

27. Install the upper ball joint into the steering knuckle (Figure 7).

28. Install the new upper ball joint nut. Using a crow's foot and a torque wrench, tighten the nut to 20 ft-lbs (27 N.m).

29. Using a crow's foot and a torque wrench, tighten the lower ball joint castle nut to 55 ft-lbs (75 N.m) and then install the new cotter pin (Figure 5).

30. Install the lower ball joint heat shield.

31. Install the ABS wheel speed sensor, if equipped.

32. Install the ABS wheel speed sensor wire routing bracket (Figure 4).





33. Install the outer tie rod stud into the steering knuckle. Start the outer tie rod attaching nut onto the tie rod stud. While holding the stud stationary, tighten the nut to 40 ft-lbs (55 N.m) using a crowfoot and socket (Figure 10).

IMPORTANT:
Ensure that the tie rod heat shield is properly positioned.

34. Align the brake rotor to the wheel studs using the mark made previously and install the brake rotor.

35. Install the brake caliper and adapter assembly over the brake rotor (Figure 2).

36. Install the caliper adapter bolts (Figure 2). Tighten the bolts to 60 ft-lbs (80 N.m).

37. Install the hub nut onto the axle shaft. With the brake applied, tighten the hub nut to 150 ft-lbs (203 N.m).

38. Install the right front wheel and tire assembly. Tighten the lug nuts to 100 ft-lbs (135 N.m).

39. Lower the vehicle and place it on an alignment rack.

40. Install the alignment equipment onto the vehicle per the alignment equipment manufacturer's instructions.

41. Adjust the front toe to the preferred specification (left or right side toe = +/- 0.12° +/-0.10°, total toe = +/- 0.24° +/- 0.20°).

42. Remove the alignment equipment.