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Fig. 9 Bushing Installer Tools

Fig. 10 Bushing And Tool Position For Installation

In Control Arm

control arm. Be sure that the flanges of the bushing are fully expanded around the control arm bushing holes.

(5) If the position of the large lower control arm pivot bushing (Fig. 11) moved during bushing installation. Install a nut and bolt through the bushing sleeve and tighten it down (Fig. 11). Using a wrench rotate the bolt until the bushing is in the correct position (Fig. 10)

BALL JOINTS

The lower front suspension ball joints operate with no free play. See Inspection Ball Joint Wear to determine if the ball joint is worn and requires replacement.

The ball joints are replaceable as an assembly, do not attempt any type of repair on the ball joint assembly. The replacement procedure for the ball joint assembly is detailed in this section.

The ball joint housing is a pressed fit into the lower control arm with the joint stud retained in the steering knuckle by a (clamp) bolt.

Fig. 11 Positioning Control Arm Bushing

INSPECTION BALL JOINT WEAR

With the weight of the vehicle resting on the road wheels. Grasp the grease fitting as shown in (Fig. 1) and with no mechanical assistance or added force attempt to move the grease fitting.

Fig. 1 Checking Ball Joint Wear

If the ball joint is worn the grease fitting will move easily. If movement is noted,replacement of the ball joint is recommended.

BALL JOINT REMOVAL

(1)Pry off seal.

(2)Position Receiving Cup Special Tool C-4699-2 to support lower control arm while receiving ball joint assembly (Fig. 2).

(3)Install Remover/Installer Special Tool, C-4699-1 (Fig. 2) over ball joint stud and against the ball joint upper housing.

(4)Press down against the ball joint upper housing, to remove ball joint assembly from lower control arm.

BALL JOINT INSTALLATION

(1) By hand, position ball joint assembly into the ball joint bore of the lower control arm. Be sure the

Fig. 2 Removing Ball Joint

ball joint assembly is not cocked in the bore of the control arm, this will cause binding of the ball joint assembly.

(2) Position assembly in press with Installer Tool C-4699-2 supporting control arm (Fig. 3).

Fig. 3 Installing Ball Joint

(3)Install the Remover/Installer, Special Tool C-4699-1 over the ball joint stud and down on the lower body of the ball joint assembly (Fig. 3).

(4)Carefully align all pieces. Using an arbor press apply pressure against the ball joint assembly, until

ball joint is fully seated against bottom surface of control arm. Do not apply excessive pressure against the control arm.

BALL JOINT SEAL INSTALLATION

(1) Support ball joint housing with Installer, Special Tool C-4699-1 (Fig. 4). Position new seal over ball joint stud and against ball joint housing.

Fig. 4 Installing Ball Joint Seal

(2) With 1-1/2 inch socket, press seal onto ball joint housing until it is squarely seated against top surface of control arm as shown in (Fig. 4).

SWAY BAR

The sway bar interconnects the front lower control arms of the vehicle and attaches to the crossmember (Fig. 1).

Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel to stabilize body roll.

Attachment to the crossmember, and front lower control arms is through rubber-isolated bushings. All parts are serviceable, and the sway bar to crossmember bushings are split for easy removal and installation. The split in the sway bar to crossmember bushing should be positioned toward the front of the vehicle.

REMOVAL

(1)Raise and support the vehicle. See Hoisting in Lubrication and Maintenance, Group 0.

(2)Remove the nuts, bolts, and sway bar retainers at the front lower control arms (Fig. 1).

(3)Remove the bolts at sway bar crossmember clamps, and remove clamps and sway bar from vehicle (Fig. 1).

INSPECTION

Inspect for broken or distorted clamps, retainers, and bushings. If bushing replacement is required, the

inner bushing can be removed by opening the split. The outer bushing must be cut or hammered off the bar. If replaced, the outer bushings should be forced on so that approximately 1/2 inch of the bar protrudes. The sway bar to crossmember bushings, should be positioned when installed, so the void on the bushing is positioned toward the rear of the vehicle (Fig. 2). Note that the control arm retainers are symmetric and bend slightly upon installation.

INSTALLATION

(1)If inspection of the sway bar assembly, determined that sway bar to lower control arm bushings require replacement. Install the new bushings, by forcing them onto sway bar using a rotating motion. Bushings should be installed on sway bar so that sway bar extends 1/2 inch out past the end of the bushing.

(2)If required position sway bar to crossmember bushings on sway bar with external rib up and void in the bushing facing the rear of vehicle (Fig. 2). Lift the bar assembly into the crossmember, and install the lower clamps and bolts. The center offset in the sway bar should be oriented toward the front of the vehicle (Fig. 1)

(3)Position bushing retainers on lower control arms, insert bolts, and install nuts. The bolts should be installed so that the threaded portion of the bolt is up, with the nut is against the lower control arm not the bushing retainer (Fig. 1).

(4)With lower control arms raised to design height, tighten all retainer attaching bolts to 70 NIm (50 ft. lbs.) torque.

(5)Lower vehicle.

Fig. 2 Sway Bar To Crossmember Bushing Position

KNUCKLE (FRONT SUSPENSION)

The front suspension knuckle (Fig. 1) provides for steering control of the vehicle. Supports the brake caliper and absorbs the loads exerted during vehicle braking. It also supports the front (driving) hub and bearing and stub axle assembly.

The front suspension knuckle also provides the ability to align the front wheels of the vehicle. This is done by allowing for front wheel camber adjustment and the ability for front tire Toe adjustments

The front suspension knuckle is not a serviceable component. Do not attempt to straighten or repair the front suspension knuckle in any way.

Service repair or replacement of the front (drive) hub and bearing, can be done with the front suspension knuckle remaining on the vehicle.

Fig. 1 Front Knuckle Assembly (Typical)

REMOVAL

(1) Remove the cotter pin, hub nut lock and spring washer from the front axle (Fig. 2).

Fig. 2 Remove Cotter Pin, Hub Nut Lock, & Spring

Washer

(2)Loosen hub nut while the vehicle is on the floor with the brakes applied (Fig. 3). The hub and driveshaft are splined together through the knuckle (bearing) and retained by the hub nut.

(3)Raise and support the vehicle. See Hoisting in Lubrication and Maintenance, Group 0.

(4)Remove the wheel lug nuts, front tire and wheel assembly and hub nut and washer.

(5)Remove the brake caliper adapter to steering knuckle attaching bolts and washers (Fig. 1). Remove the brake caliper and adapter from the steering knuckle and braking disc. Support brake caliper/adapter assembly using a wire hook and not by hydraulic hose (Fig. 4).

Fig. 3 Loosen Hub Nut

Fig. 4 Supporting Brake Caliper

(6)Remove the braking disc from the front hub/bearing assembly (Fig. 5).

(7)Remove the cotter pin and nut from the tie rod end. Remove the tie rod end from the steering knuckle arm using Puller, Special Tool C-3894-A (Fig. 6).

(8)Remove the clamp nut and bolt (Fig. 7) securing the ball joint stud into the steering knuckle.

(9)Separate ball joint stud from knuckle assembly by prying down on lower control arm. Pull knuckle assembly out and away from driveshaft (Fig. 8).

Fig. 5 Remove or Install Braking Disc

Fig. 6 Disconnect Tie Rod End

Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint, driveshaft must be supported.

(10)Remove the steering knuckle to strut damper attaching bolt and cam bolt (Fig. 9). Note the location of the cam bolt, it must be installed in the same location when steering knuckle is installed back on strut damper.

(11)Mount the steering knuckle in a vise and remove the 4 bolts on back of steering knuckle, attaching the hub and bearing assembly. Remove the hub and bearing assembly from the steering knuckle (Fig. 10).

Remove outer C/V joint seal from the steering knuckle.

Fig. 7 Remove or Install Steering Knuckle Clamp Bolt

Fig. 8 Separate Ball Joint Stud from Knuckle Assembly

(5) Slide the drive shaft back into the hub and bearing assembly and install the steering knuckle onto the ball joint stud (Fig. 13).

47 NIm (35 ft. lbs.). Install a new cotter pin into the tie rod end (Fig. 15).

Fig. 13 Installing Knuckle Assembly

(6) Install the original (or equivalent) steering knuckle to ball joint stud, clamp bolt and nut (Fig. 14). Torque the clamp bolt to 145 NIm (105 ft. lbs.).

Fig. 14 Tighten Steering Knuckle Clamp Bolt

(7) Install the tie rod end into the arm of the steering knuckle. Install the tie rod end to steering knuckle attaching nut, and torque to

Fig. 15 Install Tie Rod End

(8)Install the braking disk back on the hub and bearing assembly (Fig. 5).

(9)Install the front brake caliper and adapter back over the braking disc and align with the adapter mounting holes on steering knuckle (Fig. 1). Install

the caliper adapter to steering knuckle attaching bolts and torque to 217 NIm (160 ft. lbs.).

(10)Clean all foreign matter from the threads of the stub axle (Fig. 16). Install the washer and hub nut onto the threads of the stub axle and tighten nut.

Fig. 16 Install Washer and Hub Nut

(11)With the vehicles brakes applied to keep front

braking disc and hub from turning. Tighten the hub nut to a torque of 244 NIm (180 ft. lbs.) (Fig. 17).

(12)Install the spring washer, hub nut lock, and new cotter pin. Wrap the cotter pin prongs tightly around the hub nut lock (Fig. 18).

(13)Install the front wheel and tire assembly. Install the front wheel lug nuts and torque to 129 NIm (95 ft.lbs.).