REMOVAL & INSTALLATION
See Figures 1 and 2
- Place the steering wheel and front tires in the centered (straight ahead) position.
Any time the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.
- Remove the front wheel covers, if necessary.
- Remove the center hub nut and washer.
- Raise the van, but do not yet support it on jackstands. Be very careful when the vehicle is lifted without being supported by jackstands.
- Remove the spring tension from the upper and lower control arms. Support the lower control arm with jackstands, then lower the vehicle so that the spring is partially compressed enough to take the tension out of the spring OR compress the spring using a spring compressor tool until all spring tension is removed from the control arms. Once the correct height of the van is reached, support the vehicle frame with a second set of jackstands. The lower control arm is supported with one jackstands while teh van is supported by jackstands on teh frame; this positions the lower control arm in teh proper position for knuckle and spindle service.
- Remove the caliper, rotor and dust shield from the spindle. For more information, refer to Brakes .
- Remove the cotter pin and nut retaining the tie rod end to the spindle's lower arm. Disconnect the tie rod end with a suitable Pitman arm puller such as tool T64P-3590-F or equivalent.
- Install a hub remover/installer T81P-1104 (A, B and C adapters are needed) or equivalent. Free the hub, bearing and knuckle assembly from the halfshaft by pushing the outer CV joint shaft until it releases from the assembly.
If a spring compressor was utilized in Step 5, perform the following:
- Support the lower control arm with a hydraulic floor jack. Make sure the jack pad securely contacts the control arm. Remove the cotter pin, then loosen the nut retaining the spindle to the lower control arm ball joint. Disconnect the lower ball joint from the spindle using the same Pitman arm puller used in Step 5, then remove the tool and ball joint retaining nut.
- Slowly lower the jack under the control arm until the ball joint is disengaged from the spindle.***CAUTION***Use extreme caution when lowering the lower control arm. The coil spring may quickly expand with dangerous force. Never lower the control arm quickly.
- Remove the bolt and nut retaining the spindle to the upper control arm ball joint, then remove the spindle from the van.
If the van was lowered in order to remove the spring tension in Step 5, perform the following steps:
- Remove the retaining nut and bolt, then push up on the upper control arm until the ball joint stud is clear of the steering knuckle.
- Remove the cotter pin and nut from the lower ball joint, then, using the Pitman Arm Puller T64P-3590-F or equivalent, remove the ball joint stud from the knuckle.
- Remove the knuckle from the vehicle.To install:
- Position the steering knuckle on the CV-joint shaft. Check to see if the CV-joint shaft splines are in proper mesh.
- Position the spindle's upper arm on the upper ball joint. Install and tighten the nut and bolt to 27-37 ft. lbs. (37-50 Nm). Inspect the upper and lower ball joint boot seals for damage and replace if necessary.
- Position the spindle's lower arm over the lower ball joint stud, then slowly lift the lower control arm until the ball joint stud extends through the spindle arm and is seated in the spindle. Install the ball joint castle nut and tighten it to 80-120 ft. lbs. (108-163 Nm) for 1986-90 models, and to 59-81 ft. lbs. (80-110 Nm) for 1991-96 models. Install a new cotter pin through the castle nut. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align them.
- Connect the tie rod end to the spindle arm. Firmly seat the tie rod end stud into the tapered hole to prevent rotation while tightening the castellated nut. Torque the tie rod nut to 52-74 ft. lbs. (70-100 Nm), then install a new cotter pin. The castle nut may be tightened slightly to align the castellations with the cotter pin hole, but under no circumstances loosen the nut to align.
- Install the rotor and caliper. For more information, refer to Brakes .
- Install the front tires, then tighten the lug nuts to 85-115 ft. lbs. (116-155 Nm).
- Lower the vehicle.
- Tighten the center hub nut to 170-210 ft. lbs. (230-285 Nm).
- Install the wheel covers.