GrandCaravan 2008

Steering Knuckles

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Removal & Installation




WARNING
At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener be installed in the shock tower to take the place of an original plastic clip. It may come into contact with the strut or the coil spring.


WARNING
Wheel bearing damage will result if, after loosening the axle hub nut, the vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires for any length of time.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. With the aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut from the axle halfshaft stub shaft.
  8.  
  9. Push in on the end of the halfshaft stub shaft, disengaging its splines from the hub splines.
  10.  
  11. Access and remove the front brake rotor. Refer to Front Disc Brakes, Rotor, removal & installation.
  12.  
  13. Remove the screws (1) fastening the brake shield (3) to the steering knuckle (2), then remove the brake shield.

    Click image to see an enlarged view

    Fig. Remove the screws (1) fastening the brake shield (3) to the steering knuckle (2), then remove the brake shield

  14.  
  15. Disconnect the vehicle wiring harness from the wheel speed sensor connector.
  16.  
  17. Unclip the wheel speed sensor connector from the bracket on the frame rail.
  18.  
  19. Remove the screw fastening the wheel speed sensor routing bracket to the mounting flange on the strut.
  20.  
  21. Remove the screw fastening the wheel speed sensor routing bracket to the knuckle.
  22.  
  23. Remove the nut attaching the outer tie rod to the steering knuckle by holding the outer tie rod stud stationary while loosening and removing the nut with a wrench.
  24.  
  25. Remove the outer tie rod (3) stud from the steering knuckle (1) using Puller (2), Special Tool 9360.
    NOTE
    The strut assembly-to-knuckle attaching bolts are serrated and must not be turned during removal. Proper removal is required. Refer to the following steps for the correct method.



    Click image to see an enlarged view

    Fig. Remove the outer tie rod (3) stud from the steering knuckle (1) using Puller (2), Special Tool 9360

  26.  
  27. If servicing the left knuckle:
    1. While holding the bolt heads stationary, remove the 2 nuts (3) from the bolts (2) attaching the strut (1) to the knuckle.
    2.  
    3. Remove the 2 bolts (2) attaching the strut (1) to the knuckle using a pin punch.

      Click image to see an enlarged view

      Fig. Remove the 2 nuts (3) and the 2 bolts (2) attaching the strut (1) to the knuckle-left strut

    4.  

  28.  
  29. If servicing the right knuckle:
    1. While holding the bolt heads stationary, remove the 2 nuts (3) from the bolts (2) attaching the strut (1) to the knuckle.
    2.  
    3. Remove the 2 bolts (2) attaching the strut (1) to the knuckle using a pin punch.

      Click image to see an enlarged view

      Fig. Remove the 2 nuts (3) and the 2 bolts (2) attaching the strut (1) to the knuckle-right strut

    4.  

  30.  
  31. Tip the knuckle outward at the top and remove the halfshaft stub shaft from the hub and bearing. Suspend the halfshaft straight outward using a bungee cord or wire. Do not allow the halfshaft to hang by the inner joint.
  32.  
  33. Remove the ball joint nut using a power impact wrench. Because the tapered stud is held sufficiently in the knuckle at this time, it is not necessary to hold the stud stationary to remove the nut.
  34.  
  35. Reinstall the ball joint nut until the top of the nut is even with the top of the ball joint stud. This action will keep the stud from distorting while the stud is released from the knuckle in the following step.
    WARNING
    Do not remove the ball joint stud from the knuckle using a hammer. Damage to the ALUMINUM knuckle, ball joint, or control arm will result.


    NOTE
    Lubricate Press (2), Special Tool C-4150A, screw-drive threads before use to ease use and promote tool longevity.

  36.  
  37. Place Press (2), Special Tool C-4150A, over the ball joint stud and nut (4), as shown. Release the ball joint stud from the steering knuckle (1) by tightening the tool screw-drive. To ease the Remover installation and use, it may help to rotate the knuckle around so the inside of the knuckle faces outward.
  38.  
  39. Remove the tool and nut from the top of the ball joint stud.
  40.  
  41. Remove the steering knuckle from the vehicle.
  42.  
  43. If the hub and bearing needs to be transferred, remove the 4 bolts attaching the hub and bearing to the knuckle, then remove the hub and bearing.

    Click image to see an enlarged view

    Fig. Place Press, Special Tool C-4150A, over the ball joint stud and nut (4), as shown, for removal

  44.  

To install:

  1. If the hub and bearing needs to be installed in the knuckle, place the hub and bearing squarely into the center hole of the knuckle with the wheel speed sensor positioned toward the trailing end of the knuckle. Align the threaded mounting holes of the hub and bearing with the mounting holes in the steering knuckle, then install the 4 mounting bolts. Progressively tighten the mounting bolts in a crisscross pattern. Tighten the mounting bolts to 37 ft. lbs. (50 Nm).
    WARNING
    Before installing the knuckle on the ball joint stud, wipe the ball joint stud and the knuckle contact area free of any grease or debris, otherwise damage to the knuckle can occur. Use a clean shop cloth with MOPAR® Brake Parts Cleaner applied to it for proper cleaning. Do not spray the stud directly.

  2.  
  3. Place the knuckle (1) on the ball joint stud (2).
  4.  
  5. Install a NEW steering knuckle-to-ball joint stud nut. Tighten the nut by holding the ball joint stud (2) with a hex wrench while turning the nut with a wrench. Using a crowfoot wrench on a torque wrench, tighten the nut to 20 ft. lbs. (27 Nm), plus an additional 180° turn after the torque is met.

    Click image to see an enlarged view

    Fig. Installing the steering knuckle on the ball joint stud

  6.  
  7. Slide the halfshaft stub shaft into the hub and bearing assembly.
    WARNING
    The strut clevis-to-knuckle bolts are serrated and must not be turned during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to the following steps.


    NOTE
    If the vehicle being serviced is equipped with eccentric cam strut attaching bolts, the eccentric cam bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.


    NOTE
    The strut clevis-to-knuckle bolts are installed differently on each side. The left hand side bolts are to be installed to the vehicle rear to front. The right side bolts are to be installed to the vehicle front to rear.

  8.  
  9. If servicing the left knuckle:
    1. Position the lower end of the strut assembly (1) in line with the upper end of the knuckle, aligning the mounting holes. Install the 2 strut clevis-to-knuckle bolts (2).
    2.  
    3. Install the strut clevis-to-knuckle nuts (3) on the 2 bolts (2). While holding the bolts in place, tighten the strut clevis-to-knuckle nuts to 65 ft. lbs. (88 Nm), plus an additional 90° turn after the torque is met.
    4.  

  10.  
  11. If servicing the right knuckle:
    1. Position the lower end of the strut assembly (1) in line with the upper end of the knuckle, aligning the mounting holes. Install the 2 strut clevis-to-knuckle bolts (2).
    2.  
    3. Install the strut clevis-to-knuckle nuts (3) on the 2 bolts (2). While holding the bolts in place, tighten the strut clevis-to-knuckle nuts to 65 ft. lbs. (88 Nm), plus an additional 90° turn after the torque is met.
      WARNING
      Before installing the tie rod stud in the knuckle steering arm, wipe the stud and the knuckle contact area free of any grease or debris, otherwise damage to the knuckle can occur. Use a clean shop cloth with MOPAR® Brake Parts Cleaner applied to it for proper cleaning. Do not spray the stud directly.

    4.  

  12.  
  13. Install the outer tie rod stud into the knuckle steering arm. Start the nut onto the tie rod stud. While holding the stud stationary, tighten the nut using a wrench. Using a crowfoot wrench on a torque wrench, tighten the nut to 55 ft. lbs. (75 Nm), plus an additional 245° turn after the torque is met.
  14.  
  15. Attach the wheel speed sensor routing bracket to the knuckle. Install and tighten the screw to 71 inch lbs. (8 Nm).
  16.  
  17. Attach the wheel speed sensor routing bracket to the mounting flange on the strut assembly. Install and tighten the screw to 89 inch lbs. (10 Nm).
  18.  
  19. Clip the wheel speed sensor connector and the routing clip to the bracket on the frame rail.
  20.  
  21. Connect the vehicle wiring harness to the wheel speed sensor connector.
  22.  
  23. Install the brake shield (3) on the knuckle (2). Install and tighten the 3 mounting screws (1) to 71 inch lbs. (8 Nm).
  24.  
  25. Install the brake rotor, then install the disc brake caliper and the adapter assembly. Refer to Front Disc Brakes, Rotor, removal & installation.
  26.  
  27. Verify that the wheel speed sensor is routed properly, not allowing the cable to come into contact with any moving parts.
  28.  
  29. Install the hub nut on the end of the halfshaft stub shaft. With the aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to 118 ft. lbs. (160 Nm).
  30.  
  31. Install the tire and wheel assembly and tighten the wheel mounting nuts to 100 ft. lbs. (135 Nm).
  32.  
  33. Lower the vehicle.
  34.  
  35. Pump the brake pedal several times to ensure the vehicle has a firm brake pedal before moving the vehicle.
  36.  
  37. Check and adjust the brake fluid level, as necessary.
  38.  
  39. Perform a wheel alignment.
  40.  

 
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