ION, L-Series, S-Series 1999-2005

Steering Knuckle

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Removal & Installation



  1. With vehicle on the ground, depress the brake pedal and loosen the axle to hub nut.
    CAUTION
    Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  2.  
  3. Raise the vehicle on a hoist.
  4.  
  5. Remove the wheel and tire assembly.

    Click image to see an enlarged view

    Fig. Remove caliper mount bracket-to-steering knuckle bolts; remove the caliper assembly and suspend it from the strut spring with mechanics wire

  6.  
  7. Remove caliper mount bracket-to-steering knuckle bolts; remove the caliper assembly and suspend it from the strut spring with mechanics wire.
  8.  
  9. Remove the rotor.
    NOTE
    Do not remove fasteners at this time.

  10.  
  11. Loosen the steering knuckle-to-strut fasteners.
  12.  
  13. Remove the axle nut and washer, but do not attempt to remove the axle.

    Click image to see an enlarged view

    Fig. Loosen the ball stud castle nut, until top of the castle nut is level with the top of ball the stud

  14.  
  15. Remove and discard the lower control arm ball stud cotter pin.
  16.  
  17. Loosen the ball stud castle nut, until top of the castle nut is level with the top of ball the stud.
  18.  
  19. Remove the torque prevailing nut and discard the nut. A new nut will be required during assembly.
    NOTE
    On ABS equipped vehicles, the outer CV joint has a speed sensor ring. Using the incorrect tool or procedure to separate the control arm from the knuckle can damage the ring, resulting in a loss of ABS operation.


    NOTE
    Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.


    NOTE
    Lubricate threads of tool forcing screw using thread lube before each use.



    Click image to see an enlarged view

    Fig. Using the special tool SA9132S (or equivalent), separate the lower control arm from the steering knuckle

  20.  
  21. Using the special tool SA9132S (or equivalent), separate the lower control arm from the steering knuckle.
  22.  
  23. Remove the lower control arm ball stud castle nut.
    NOTE
    Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

  24.  
  25. Using the special tool SA91100C (or equivalent), separate the rod end from the steering knuckle.

    Click image to see an enlarged view

    Fig. If equipped with ABS, disconnect the electrical connector at ABS wheel speed sensor

  26.  
  27. If equipped with ABS, disconnect the electrical connector at ABS wheel speed sensor.

    Click image to see an enlarged view

    Fig. Support or suspend drive axle assembly and remove the two strut-to-steering knuckle fasteners

  28.  
  29. Support or suspend drive axle assembly.
  30.  
  31. Remove the 2 strut-to-steering knuckle fasteners.
    NOTE
    Never pull on the shaft assembly.


    NOTE
    If difficulty is encountered in separating axle from hub, tap on end of drive axle shaft using a block of wood and a hammer. Do not hammer directly on end of axle.

  32.  
  33. Remove the knuckle/wheel hub assembly from vehicle.
  34.  

To install:

  1. Position steering knuckle onto axle shaft and install axle to hub washer and a NEW nut.
    NOTE
    Do not tighten nut at this time.

  2.  
  3. Install ball joint stud through knuckle attachment point and install castle nut.
    NOTE
    Do not tighten nut at this time.

  4.  
  5. Attach steering knuckle-to-strut with fasteners.
    NOTE
    Tie rod end threads must be thoroughly cleaned before tightening nut. Do not lubricate any portion of the stud.


    NOTE
    Use new nut. Torque retention of old nut may not be sufficient.

  6.  
  7. Seat tie rod end into steering knuckle by using special tool J44015 or equivalent.
  8.  
  9. Tighten the tie rod linkage installer to 33 ft. lbs. (45 Nm).
    NOTE
    This procedure requires special tool SA9140E (or equivalent).

  10.  
  11. Tighten new torque prevailing nut.
  12.  
  13. Tighten tie rod-to-steering knuckle nut to 18 ft. lbs. (25 Nm) plus 90 degrees.
    NOTE
    With fasteners installed but not tightened, push bottom of strut inward while tightening fasteners.

  14.  
  15. Tighten the steering knuckle-to-strut fastener to 126 ft. lbs. (170 Nm).
    NOTE
    If it is necessary to rotate the castle nut after tightening to orient it to the hole in the stud, always tighten the nut to align it; never loosen it.

  16.  
  17. Tighten the ball joint stud castle nut to 55 ft. lbs. (75 Nm).
  18.  
  19. Install new cotter pin.
  20.  
  21. Install rotor onto wheel hub.
  22.  
  23. Install caliper mount bracket onto knuckle, and tighten the caliper mount bracket-to-steering knuckle to 81 ft. lbs. (110 Nm).
  24.  
  25. If equipped with ABS, install electrical connector to ABS wheel speed sensor.
  26.  
  27. Depress brake pedal and tighten axle to hub nut to 148 ft. lbs. (200 Nm).
    NOTE
    Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors/drums. Failure to do so can cause wheel nuts to loosen in service.

  28.  
  29. Position wheel onto hub.
  30.  
  31. Install wheel nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct. Tighten the wheel nuts to 103 ft. lbs. (140 Nm).
  32.  
  33. Lower vehicle from hoist.
  34.  
  35. Perform vehicle wheel alignment.
  36.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake rotor. Refer to

    Click image to see an enlarged view

    Fig. Remove the ABS sensor bracket bolt from the steering knuckle

  6.  
  7. If equipped with ABS, remove the ABS sensor bracket bolt from the steering knuckle.
    NOTE
    The ABS sensor bracket is equipped with a locating pin. Do not break this pin.

  8.  
  9. Carefully remove the ABS sensor bracket assembly from the steering knuckle.

    Click image to see an enlarged view

    Fig. Remove the drive axle to hub nut

  10.  
  11. Remove the drive axle to hub nut. Discard the nut.
  12.  
  13. Disengage the drive axle from the steering knuckle.
  14.  
  15. Remove the outer tie rod to knuckle nut.
  16.  
  17. Using the special tool SA91100C, separate the tie rod from the steering knuckle.

    Click image to see an enlarged view

    Fig. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut

  18.  
  19. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut.
  20.  
  21. Lower the control arm to separate the ball stud from the steering knuckle.
  22.  
  23. Support and protect the drive axle during steering knuckle removal.
  24.  
  25. Remove the strut to steering knuckle bolts and nuts.
  26.  
  27. Remove the steering knuckle from the vehicle.
  28.  
  29. Remove the hub/bearing from the steering knuckle.
  30.  

To install:

  1. Install the hub/bearing to the steering knuckle.
  2.  
  3. Position the steering knuckle on the lower control arm ball stud, while guiding the drive axle through the steering knuckle hub/bearing.
  4.  
  5. Install new strut to knuckle nuts and bolts. Snug the bolts only at this time.
  6.  
  7. Install the lower control arm ball stud to steering knuckle pinch bolt and nut, and tighten the bolt and nut to 74 ft. lbs. (100 Nm).
  8.  
  9. Using the special tool J44015, install the tie rod to the steering knuckle. Set the taper by tightening the special tool J44015to 33 ft. lbs. (45 Nm).
    NOTE
    Do not allow the ball stud to turn when installing the tie rod to steering knuckle nut.

  10.  
  11. Remove the special tool J44015and install a new tie rod to steering knuckle nut.
  12.  
  13. Tighten the nut to 45 ft. lbs. (60 Nm).
  14.  
  15. Inspect the tie rod boot for damage, replace if necessary.
    NOTE
    The ABS sensor bracket has a locating pin. The pin must be lactated in the steering knuckle locating hole.

  16.  
  17. If equipped with ABS, install the ABS sensor assembly to the steering knuckle, and tighten the ABS sensor bracket bolt to 71 inch lbs.(8 Nm).
  18.  
  19. Install the brake rotor and hydraulic brake caliper.
  20.  
  21. Install the washer and a new hub/bearing nut to the drive axle, and tighten the nut to 85 ft. lbs. (115 Nm).
  22.  
  23. Back of the nut and tighten to 15 ft. lbs. (20 Nm) plus an additional 90 degrees.
  24.  
  25. Install a new cotter pin through the alignment hole in the drive axle. Rotate the drive axle nut clockwise as necessary to align the castle nut slots.
  26.  
  27. Install the tire and wheels.
  28.  
  29. Lower the vehicle.
  30.  
  31. Align the front end.
  32.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel bearing.

    Click image to see an enlarged view

    Fig. Remove the outer tie rod to knuckle nut

  4.  
  5. Remove the outer tie rod to knuckle nut.
  6.  
  7. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
    NOTE
    Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.



    Click image to see an enlarged view

    Fig. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut

  8.  
  9. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut.
  10.  
  11. Lower the lower control arm to separate the ball stud from the steering knuckle. If necessary, use the special tool J43631 .
  12.  
  13. Remove the strut to steering knuckle nuts and bolts.

    Click image to see an enlarged view

    Fig. Remove the steering knuckle from the vehicle

  14.  
  15. Remove the steering knuckle from the vehicle.
  16.  

To install:

  1. Position the steering knuckle onto the lower control arm ball stud, while guiding the axle through the knuckle.
  2.  
  3. Install the strut to knuckle bolts and nuts, and tighten the bolts and nuts to 89 ft. lbs. (120 Nm).
    NOTE
    The torque sequence must be followed in the order that is listed.

  4.  
  5. Install the lower control arm ball stud to steering knuckle pinch bolt and nut.
  6.  
  7. Tighten the pinch bolt and nut in the following sequence:

    First Pass: Tighten the nut to 37 ft. lbs. (50 Nm).
     
    Reverse nut three-quarters turn
     
    Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm) plus 30 degrees.
     

  8.  
  9. Install the outer tie rod to the steering knuckle, and tighten the nut to 18 ft. lbs. (25 Nm) plus 90 degrees.
  10.  
  11. Install the wheel bearing, brake rotor, brake caliper and front wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Road test the vehicle in order to verify alignment.
  16.  

  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel bearing.

    Click image to see an enlarged view

    Fig. Remove the outer tie rod to knuckle nut

  4.  
  5. Remove the outer tie rod to knuckle nut.
  6.  
  7. Using the special tool SA91100C, separate the tie rod from the steering knuckle.
    NOTE
    Do not free the ball stud by using a pickle fork or a wedge-type tool. Damage to the seal or bushing may result.



    Click image to see an enlarged view

    Fig. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut

  8.  
  9. Remove the lower control arm ball stud to steering knuckle pinch bolt and nut.
  10.  
  11. Lower the lower control arm to separate the ball stud from the steering knuckle. If necessary, use the special tool J43631 .
  12.  
  13. Remove the strut to steering knuckle nuts and bolts.

    Click image to see an enlarged view

    Fig. Remove the steering knuckle from the vehicle

  14.  
  15. Remove the steering knuckle from the vehicle.
  16.  

To install:

  1. Position the steering knuckle onto the lower control arm ball stud, while guiding the axle through the knuckle.
  2.  
  3. Install the strut to knuckle bolts and nuts, and tighten the bolts and nuts to 89 ft. lbs. (120 Nm).
    NOTE
    The torque sequence must be followed in the order that is listed.

  4.  
  5. Install the lower control arm ball stud to steering knuckle pinch bolt and nut.
  6.  
  7. Tighten the pinch bolt and nut in the following sequence:

    First Pass: Tighten the nut to 37 ft. lbs. (50 Nm).
     
    Reverse nut three-quarters turn
     
    Second Pass: Tighten the nut to 37 ft. lbs. (50 Nm) plus 30 degrees.
     

  8.  
  9. Install the outer tie rod to the steering knuckle, and tighten the nut to 18 ft. lbs. (25 Nm) plus 90 degrees.
  10.  
  11. Install the wheel bearing, brake rotor, brake caliper and front wheels.
  12.  
  13. Lower the vehicle.
  14.  
  15. Road test the vehicle in order to verify alignment.
  16.  

 
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