300, 300C & Magnum 2006-2008, Charger 2006-2008

Knuckles

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Removal & Installation



All Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove wheel mounting nuts, then tire and wheel assembly.
  6.  
  7. While a helper applies brakes to keep hub from rotating, remove hub nut from axle halfshaft.
  8.  
  9. Remove clip fastening wheel speed sensor to knuckle.
  10.  
  11. Remove screw fastening wheel speed sensor to knuckle. Pull sensor head out of knuckle.
  12.  
  13. Access and remove front brake rotor.
  14.  
  15. Remove nut from outer tie rod end stud.
  16.  
  17. Separate tie rod stud from knuckle.
  18.  
  19. Loosen nut attaching lower control arm ball joint stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using puller in next step.
    WARNING
    In following step, use care not to damage ball joint seal boot.

  20.  
  21. Separate ball joint stud from knuckle.
  22.  
  23. Remove tool.
  24.  
  25. Remove nut from end of ball joint stud.
  26.  
  27. Loosen nut attaching upper ball joint stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step.
    WARNING
    In following step, use care not to damage ball joint seal boot.

  28.  
  29. Separate upper ball joint stud from knuckle.
  30.  
  31. Remove tool.
  32.  
  33. Remove nut from end of upper ball joint stud.
  34.  
  35. Slide knuckle off halfshaft and remove from vehicle.
  36.  

To install:

  1. Place knuckle over lower ball joint stud and guide hub and bearing onto axle halfshaft.
  2.  
  3. Start NEW nut on lower ball joint stud. Do not tighten at this time.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  4.  
  5. Place upper ball joint stud through hole in top of knuckle and install nut. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 35 ft. lbs. (47 Nm) +90°.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  6.  
  7. Tighten lower ball joint nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 50 ft. lbs. (68 Nm) +90°.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  8.  
  9. Place outer tie rod stud through hole in knuckle and install nut. Tighten nut by holding stud with a wrench while turning nut with another wrench. Tighten nut using crow foot wrench on torque wrench to 63 ft. lbs. (85 Nm).
  10.  
  11. Install brake rotor, then disc brake caliper and adapter assembly.
  12.  
  13. Install hub nut on end of axle halfshaft. While a helper applies brakes to keep hub from turning, tighten hub nut to 157 ft. lbs. (213 Nm).
  14.  
  15. Install wheel speed sensor head into knuckle and install mounting screw. Tighten screw to 95 inch lbs. (11 Nm).
  16.  
  17. Attach wheel speed sensor cable routing clip at knuckle.
  18.  
  19. Install tire and wheel assembly. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm).
  20.  
  21. Lower vehicle.
  22.  
  23. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  24.  
  25. Check and adjust brake fluid level in reservoir as necessary.
  26.  
  27. Perform wheel alignment.
  28.  

Rear Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove wheel mounting nuts, then tire and wheel assembly.
  6.  
  7. Remove screw fastening wheel speed sensor to knuckle. Pull sensor head out of knuckle.
  8.  
  9. Remove wheel speed sensor cable routing clip from brake flex hose routing bracket.
  10.  
  11. Remove screw fastening brake flex hose routing bracket to knuckle.
  12.  
  13. Access and remove front brake rotor.
  14.  
  15. Remove nut from outer tie rod end stud.
  16.  
  17. Using a separator, separate tie rod stud from knuckle.
  18.  
  19. Loosen nut attaching upper ball joint stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting in next step.
    WARNING
    In following step, use care not to damage ball joint seal boot while sliding the separator into place past seal boot.

  20.  
  21. Separate upper ball joint stud from knuckle.
  22.  
  23. Remove nut from end of upper ball joint stud.
  24.  
  25. Loosen nut attaching tension strut ball joint stud to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step.
    WARNING
    In following step, use care not to damage ball joint seal boot.

  26.  
  27. Separate tension strut ball joint stud from knuckle.
  28.  
  29. Remove nut from end of tension strut ball joint stud.
  30.  
  31. Loosen nut attaching ball joint stud to lower control arm. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step.
    WARNING
    In following step, use care not to damage ball joint seal boot.

  32.  
  33. Separate ball joint stud from lower control arm.
  34.  
  35. Remove nut from end of ball joint stud attaching lower control arm to knuckle.
  36.  
  37. Remove knuckle from vehicle.
  38.  

To install:

Click image to see an enlarged view

Fig. Before installing knuckle on lower control arm, measure height of ball joint seal boot (1) mounted on knuckle

  1. Before installing knuckle on lower control arm, measure height of ball joint seal boot mounted on knuckle. If seal boot height is above 25.5 mm, any air inside seal boot must be expelled. To do so, follow these steps.
    1. Tip ball joint stud completely to one side.
    2.  
    3. Using thumb and index finger, gently squeeze seal boot together at center expelling any air. Do not allow grease to be release.
    4.  
    5. Push down very top of seal boot.
    6.  
    7. Return ball joint stud to original -centered- position.
    8.  
    9. Measure ball joint seal boot height (1) making sure it is within specification.
    10.  
    11. Wipe any grease from ball joint stud.
    12.  

  2.  
  3. Place knuckle over lower ball joint studs on vehicle and loosely install NEW nuts by hand.
    WARNING
    It is important to tighten nuts as described in following steps to avoid damaging ball stud joints.

  4.  
  5. Completely install NEW nut on ball joint stud attaching lower control arm to knuckle. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 50 ft. lbs. (68 Nm) + 90°.
  6.  
  7. Completely install NEW nut on ball joint stud attaching tension strut to knuckle. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 50 ft. lbs. (68 Nm) + 90°.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  8.  
  9. Place upper ball joint stud through hole in top of knuckle and install nut. Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 35 ft. lbs. (47 Nm) + 90°.
    WARNING
    It is important to tighten nut as described in following step to avoid damaging ball stud joint.

  10.  
  11. Place outer tie rod stud through hole in knuckle and install nut. Tighten nut by holding stud with a wrench while turning nut with another wrench. Tighten nut using crow foot wrench on torque wrench to 63 ft. lbs. (85 Nm).
  12.  
  13. Install brake rotor, then disc brake caliper and adapter assembly.
  14.  
  15. Install screw fastening brake flex hose routing bracket to knuckle. Tighten screw to 106 inch lbs. (12 Nm).
  16.  
  17. Install wheel speed sensor head into knuckle and install mounting screw. Tighten screw to 95 inch lbs. (11 Nm).
  18.  
  19. Attach wheel speed sensor cable and routing clip to brake flex hose routing bracket.
  20.  
  21. Install tire and wheel assembly. Tighten wheel mounting nuts to 110 ft. lbs. (150 Nm).
  22.  
  23. Lower vehicle.
  24.  
  25. Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
  26.  
  27. Check and adjust brake fluid level in reservoir as necessary.
  28.  
  29. Perform wheel alignment.
  30.  

 
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