Mazda Trucks 1987-1993 Repair Guide

Knuckle and Spindle

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REMOVAL & INSTALLATION



Pickup 2WD Models

SeeChapter 7for servicing 4WD models.

  1. Raise and support the front end on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove brake calipers. Suspend the calipers out of the way with a wire. Don't disconnect the brake line.
  6.  
  7. Remove the brake rotor, hub and bearings.
  8.  
  9. Remove the tie rod-to-knuckle nut, and, using a ball joint separator, remove the tie rod end from the knuckle.
  10.  
  11. Support the lower arm with a floor jack.
  12.  
  13. Remove the cotter pin and nut from the lower ball joint, and, using a ball joint separator, disconnect the lower ball joint from the knuckle.
  14.  
  15. Remove the cotter pin and nut from the upper ball joint, and, using a ball joint separator, disconnect the upper ball joint from the knuckle.
  16.  
  17. Pull the knuckle and spindle assembly from the control arms.
  18.  
  19. The knuckle arm may now be removed.
  20.  
  21. Clean and inspect all parts for wear or damage. Replace parts as necessary.
  22.  
  23. Secure the knuckle in a vise and install the knuckle arm, if removed. Torque the bolts to 70-74 ft. lbs.
  24.  
  25. Install the knuckle assembly on the ball joints and secure the mounting nuts. Install the tie rod to knuckle arm, and install the remaining components. Observe the following torques.

    Upper ball joint-to-knuckle: 35-38 ft. lbs.
     
    Lower ball joint-to-knuckle: 116 ft. lbs.
     
    Tie rod end-to-knuckle: 22-29 ft. lbs.
     

  26.  

MPV Models

REAR WHEEL DRIVE
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel assembly.
  4.  
  5. Remove the wheel hub/bearing assembly, if necessary.
  6.  
  7. Remove the brake caliper.
  8.  
  9. Remove the disc plate.
  10.  
  11. Disconnect the tie-rod end from the knuckle/spindle.
  12.  
  13. Disconnect the lower arm.
  14.  
  15. Remove the knuckle/spindle assembly.
  16.  

To install:
  1. Install the knuckle/spindle assembly. Torque the strut mounting nut to 69-86 ft. lbs. (94-116 Nm).
  2.  
  3. Install the lower arm, ball joint to the knuckle/spindle assembly. Torque the ball joint nut to 87-115 ft. lbs. (118-156 Nm).
  4.  
  5. Connect the tie-rod end, torque the nut to 44-57 ft. lbs. (59-78 Nm).
  6.  
  7. Install wheel hub/bearing assembly, if removed.
  8.  
  9. Install the disc plate.
  10.  
  11. Install the brake caliper, torque the mounting bolts to 66-79 ft. lbs. (89-107 Nm).
  12.  
  13. Install the locknut, torque to 131-173 ft. lbs. (117-235 Nm).
  14.  
  15. Install the hub dust cap.
  16.  
  17. Install the wheel assembly.
  18.  
  19. Lower the vehicle.
  20.  

4-WHEEL DRIVE
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the wheel assembly.
  4.  
  5. Remove the locknut.
  6.  
  7. Remove the brake caliper.
  8.  
  9. Remove the disc plate retaining screw(s).
  10.  
  11. Disconnect the tie-rod end from the knuckle.
  12.  
  13. Disconnect the lower ball joint.
  14.  
  15. Remove the disc plate.
  16.  
  17. Remove the ball joint mounting nuts and bolts.
  18.  
  19. Remove the knuckle, wheel hub and dustplate as an assembly.
  20.  
  21. Remove the wheel bearings from the hub assembly, if needed.
  22.  

To install:
  1. Install wheel bearings to the hub assembly, if removed.
  2.  
  3. Install the knuckle assembly. Torque the strut mounting nut to 69-86 ft. lbs. (94-116 Nm).
  4.  
  5. Install the ball joint mounting nuts and bolts. Torque the upper mounting bolts to 76-101 ft. lbs. (102-137 Nm). Torque the through-bolt nut to 95-106 ft. lbs. (128-171 Nm).
  6.  
  7. Replace the disc plate.
  8.  
  9. Install ball joint to the knuckle assembly. Torque the ball joint nut to 116-137 ft. lbs. (157-186 Nm).
  10.  
  11. Connect the tie-rod end, torque the nut to 44-57 ft. lbs. (59-78 Nm).
  12.  
  13. Install the brake caliper, torque the mounting bolts to 66-79 ft. lbs. (89-107 Nm).
  14.  
  15. Install the disc plate retaining nut.
  16.  
  17. Install the locknut, torque to 174-231 ft. lbs. (236-313 Nm).
  18.  
  19. Install the wheel assembly.
  20.  
  21. Lower the vehicle.
  22.  

Navajo

REAR WHEEL DRIVE

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Front spindle removal/installation

  1. Raise the front of the vehicle and install jackstands.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the caliper assembly from the rotor and hold it out of the way with wire.
  6.  
  7. Remove the dust cap, cotter pin, nut, nut retainer, washer, and outer bearing, and remove the rotor from the spindle.
  8.  
  9. Remove inner bearing cone and seal. Discard the seal.
  10.  
  11. Remove brake dust shield.
  12.  
  13. Disconnect the steering linkage from the spindle and spindle arm by removing the cotter pin and nut.
  14.  
  15. With Tie Rod removal tool 3290-D or equivalent remove the tie rod end from the spindle arm.
  16.  
  17. Remove the cotter pin and the castellated nut from the lower ball joint stud.
  18.  
  19. Remove the axle clamp bolt from the axle. Remove the camber adjuster from the upper ball joint stud and axle beam.
  20.  
  21. Strike the area inside the top of the axle to pop the lower ball joint loose from the axle beam.
  22.  
  23. Remove the spindle and the ball joint assembly from the axle.
  24.  


WARNING
Do not use a ball joint fork to separate the ball joint from the spindle, as this will damage the seal and the ball joint socket!

To install:

A 3 step sequence for tightening ball joint stud nuts must be followed to avoid excessive turning effort of spindle about axle.

  1. Prior to assembly of the spindle, make sure the upper and lower ball joints seals are in place.
  2.  
  3. Place the spindle and the ball joint assembly into the axle.
  4.  
  5. Install the camber adjuster in the upper over the upper ball joint. If camber adjustment is necessary, special adapters must be installed.
  6.  
  7. Tighten the lower ball joint stud to 95-110 ft. lbs. Continue tightening the castellated nut until it lines up with the hole in the ball joint stud. Install the cotter pin. Install the dust shield.
  8.  
  9. Pack the inner and outer bearing cones with high temperature wheel bearing grease. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers.
  10.  
  11. Install the inner bearing cone and seal. Install the hub and rotor on the spindle.
  12.  
  13. Install the outer bearing cone, washer, and nut. Adjust bearing endplay and install the cotter pin and dust cap.
  14.  
  15. Install the caliper.
  16.  
  17. Connect the steering linkage to the spindle. Tighten the nut to 52-74 ft. lbs. and advance the nut as required for installation of the cotter pin.
  18.  
  19. Install the wheel and tire assembly. Lower the vehicle. Check, and if necessary, adjust the toe setting.
  20.  

4-WHEEL DRIVE
  1. Raise the vehicle and support on jackstands.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the caliper.
  6.  
  7. Remove hub locks, wheel bearings, and locknuts.
  8.  
  9. Remove the hub and rotor. Remove the outer wheel bearing cone.
  10.  
  11. Remove the grease seal from the rotor with seal remover tool 1175-AC and slide hammer 750T-100-A or equivalent. Discard seal and replace with a new one upon assembly.
  12.  
  13. Remove the inner wheel bearing.
  14.  
  15. Remove the inner and outer bearing cups from the rotor with a bearing cup puller.
  16.  
  17. Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or rawhide hammer to jar the spindle from the knuckle. Remove the splash shield.
  18.  
  19. On the left side of the vehicle remove the shaft and joint assembly by pulling the assembly out of the carrier.
  20.  
  21. On the right side of the carrier, remove and discard the keystone clamp from the shaft and joint assembly and the stub shaft. Slide the rubber boot onto the stub shaft and pull the shaft and joint assembly from the splines of the stub shaft.
  22.  
  23. Place the spindle in a vise on the second step of the spindle. Wrap a shop towel around the spindle or use a brass-jawed vise to protect the spindle.
  24.  
  25. Remove the oil seal and needle bearing from the spindle with slide hammer T50T-100-A and seal remover tool 1175-A-C or equivalent.
  26.  
  27. If required, remove the seal from the shaft, by driving off with a hammer.
  28.  
  29. If the tie rod has not been removed, then remove cotter pin from the tie rod nut and then remove nut. Tap on the tie rod stud to free it from the steering arm.
  30.  
  31. Remove the upper ball joint cotter pin and nut. Loosen the lower ball joint nut to the end of the stud.
  32.  
  33. Strike the inside of the spindle near the upper and lower ball joints to break the spindle loose from the ball joint studs.
  34.  
  35. Remove the camber adjuster sleeve. If required, use pitman arm puller, T64P-3590-F or equivalent to remove the adjuster out of the spindle. Remove the lower ball joint nut.
  36.  
  37. Place knuckle in vise and remove snapring from bottom ball joint socket if so equipped.
  38.  
  39. Assemble the C-frame, T74P-4635-C, forcing screw, D79T-3010-AE and ball joint remover T83T-3050-A or equivalent on the lower ball joint.
  40.  
  41. Turn forcing screw clockwise until the lower ball joint is removed from the steering knuckle.
  42.  
  43. Repeat Steps 20 and 21 for the upper ball joint.
  44.  

Always remove lower ball joint first.

To install:
  1. Clean the steering knuckle bore and insert lower ball joint in knuckle as straight as possible. The lower ball joint doesn't have a cotter pin hole in the stud.
  2.  
  3. Assemble the C-frame, T74P-4635-C, forcing screw, D790T-3010-AE, ball joint installer, T83T-3050-A and receiver cup T80T-3010-A3 or equivalent tools, to install the lower ball joint.
  4.  
  5. Turn the forcing screw clockwise until the lower ball joint is firmly seated. Install the snapring on the lower ball joint.
  6.  

If the ball joint cannot be installed to the proper depth, realignment of the receiver cup and ball joint installer will be necessary.

  1. Repeat Steps 24 and 25 for the upper ball joint.
  2.  
  3. Install the camber adjuster into the support arm. Position the slot in its original position.
  4.  


CAUTION
The following torque sequence must be followed exactly when securing the spindle. Excessive spindle turning effort may result in reduced steering returnability if this procedure is not followed.

  1. Install a new nut on the bottom of the ball joint stud and torque to 90 ft. lbs. (minimum). Tighten to align the nut to the next slot in the nut with the hole in the ball joint stud. Install a new cotter pin.
  2.  
  3. Install the snapring on the upper ball joint stud. Install the upper ball joint pinch bolt and torque the nut to 48-65 ft. lbs.
  4.  

The camber adjuster will seat itself into the knuckle at a predetermined position during the tightening sequence. Do not attempt to adjust this position.

  1. Clean all dirt and grease from the spindle bearing bore. Bearing bores must be free from nicks and burrs.
  2.  
  3. Place the bearing in the fore with the manufacturer's identification facing outward. Drive the bearing into the bore using spindle replacer, T80T-4000S and driver handle T80T-4000-W or equivalent.
  4.  
  5. Install the grease seal in the bearing bore with the lip side of the seal facing towards the tool. Drive the seal in the bore with spindle bearing replacer, T83T-3123-A and driver handle T80-4000-W or equivalent. Coat the bearing seal lip with Lubriplate®.
  6.  
  7. If removed, install a new shaft seal. Place the shaft in a press, and install the seal with spindle/axle seal installer, T83T-3132-A, or equivalent.
  8.  
  9. On the right side of the carrier, install the rubber boot and new keystone clamps on the stub slip yoke.
  10.  

This axle does not have a blind spline. Therefore, special attention should be made to assure that the yoke ears are in line during assembly.

  1. Slide the boot over the assembly and crimp the keystone clamp using keystone clamp pliers, T63P-9171-A or equivalent.
  2.  
  3. On the left side of the carrier slide the shaft and joint assembly through the knuckle and engage the splines on the shaft in the carrier.
  4.  
  5. Install the splash shield and spindle onto the steering knuckle. Install and tighten the spindle nuts to 40-50 ft. lbs.
  6.  
  7. Drive the bearing cups into the rotor using bearing cup replacer T73T-4222-B and driver handle, T80T-4000-W or equivalent.
  8.  
  9. Pack the inner and outer wheel bearings and the lip of the oil seal with Multi-Purpose Long-Life Lubricant, C1AZ-19590-B or equivalent.
  10.  
  11. Place the inner wheel bearing in the inner cup. Drive the grease seal into the bore with hub seal replacer, T80T-4000-T and driver handle, T80T-4000-W or equivalent. Coat the bearing seal lip with multipurpose long life lubricant, C1AZ-19590-B or equivalent.
  12.  
  13. Install the rotor on the spindle. Install the outer wheel bearing into cup.
  14.  

Verify that the grease seal lip totally encircles the spindle.

  1. Install the wheel bearing, locknut, thrust bearing, snapring, and locking hubs.
  2.  

 
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