CAUTION: Proper service and
repair procedures are essential for
safe and reliable installation of chas-
sis parts, and require experience and
tools specially designed for the pur-
pose. These parts MUST be installed
by a qualified mechanic, otherwise
an unsafe vehicle and/or personal
injury could result.
WARNING: Before attempting to
remove the stud from the steering
knuckle, make sure the stud of the
old ball joint was firmly seated in the
tapered hole of the steering knuckle.
If the ball joint was loose in the
steering knuckle, or if any out-of-
roundness, deformation, or damage
is observed, the STEERING
KNUCKLE MUST BE REPLACED.
Failure to replace a damaged or worn
steering knuckle may cause loss of
steering ability since the ball joint
STUD MAY BREAK and cause the
wheel to separate from the vehicle.
1. Raise and support the vehicle
under the lower control arm.
2. Remove the wheel and tire
assembly.
3. On 4WD vehicles remove the
drive shaft axle nut.
4. Remove the two bolts securing
the disc brake caliper adapter to
the steering knuckle. Remove
caliper and caliper adapter assem-
bly and secure out of the way.
INSTALLATION INSTRUCTIONS
FORM NUMBER
4563
The steering knuckle must be
replaced in any and all cases of
broken, bent, or loose ball joint
studs in knuckle.
!
!
NOTE: DO NOT allow caliper to
hang by flex hose.
5. Remove the wheel speed sensor
bracket bolt from the upper con-
trol arm.
6. Disconnect the wheel speed
sensor harness from the upper
control arm.
7. Remove the wheel speed sensor
wire from the body.
NOTE: Mark the holes used to
mount the speed sensor electri-
cal connector before removing.
This will ensure the proper loca-
tion of the speed sensor electri-
cal connector for installation.
8. Disconnect the wheel speed
sensor harness from the chassis
harness.
9. To ensure the ease of removal,
bundle speed sensor wiring har-
ness and tie to knuckle. This will
prevent the harness from getting
entangled in any of the
suspension
components during
removal
of the knuckle.
10. Remove the outer tie rod nut
from the steering knuckle. Using
a suitable tool separate the tie
rod from the knuckle.
11. Remove the lower ball joint
retaining nut from the stud and
install hand tight.
12. Remove the upper ball joint
retaining nut from the stud and
install hand tight.
13. Using a suitable tool, separate
the studs from the tapered holes
in the knuckle for both the upper
and lower ball joints.
14. On 4WD vehicles support the
front half shaft with a wire. This
is to prevent the shaft from over-
extending when the steering
knuckle is removed.
15. Remove the upper and lower ball
joint stud nuts. Remove knuckle
and set aside.
16. Remove the ball joint nuts and
bolts from the lower control arm
and discard.
17. Remove the lower ball joint from
the control arm.
18. Examine the ball joint mounting
area of the control arm and make
sure it is clean and free of cracks.
WARNING: If any cracks or other
damage is found, the control arm
must be replaced. Failure to
replace a cracked or damaged
control arm may cause loss of
steering ability or cause the wheel
to separate from the vehicle.
19. Clean steering knuckle and ball
joint tapers. Insert new ball joint
stud into steering knuckle by
hand and check fit of stud taper
to the knuckle. Stud should seat
firmly without any rocking. Only
the threads of the stud should
extend through the steering
knuckle. If the parts do not meet
these requirements either the
steering knuckle is worn and
needs replacement or incorrect
parts are being used.
!
