Mazda Trucks 1994-1998 Repair Guide

Knuckle and Spindle

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REMOVAL & INSTALLATION



Navajo and 1994-97 B Series Pick-up
REAR WHEEL DRIVE

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Navajo spindle removal-B Series Pick-up similar

  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 brake dust shield.
  10.  
  11. Disconnect the steering linkage from the spindle and spindle arm by removing the cotter pin and nut.
  12.  
  13. With Tie Rod removal tool 3290-D or equivalent remove the tie rod end from the spindle arm.
  14.  
  15. If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
  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.  


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!

  1. Remove the spindle and the ball joint assembly from the axle.
  2.  

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 104-146 ft. lbs. (141-198 Nm) for 1994 models and 89-133 ft. lbs. (120-180 Nm) for 1995-97 models. 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. If removed, install the front wheel ABS sensor and wire harness to the steering knuckle.
  10.  
  11. Install the hub and rotor on the spindle.
  12.  
  13. Install the outer bearing cone, washer, and nut. Adjust bearing end-play 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. (70-100 Nm) 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 and locknuts.
  8.  
  9. Remove the hub and rotor. Ensure that the wheel bearings do not fall out.
  10.  
  11. 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.
  12.  
  13. Remove the axle shaft for the side of the vehicle you are working on. Refer to Drive Train for axle shaft removal procedures.
  14.  
  15. Remove the cotter pin from the tie rod nut and then remove the nut. Tap on the tie rod stud to free it from the steering arm.
  16.  
  17. Remove the upper ball joint cotter pin and nut. Loosen the lower ball joint nut to the end of the stud.
  18.  
  19. Strike the inside of the spindle near the upper and lower ball joints to break the spindle loose from the ball joint studs.
  20.  
  21. 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.
  22.  
  23. Remove the steering knuckle from the I-beam end.
  24.  

To install:
  1. Install the steering knuckle to the I-beam end, engaging both upper and lower ball joints studs in their respective holes.
  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. Install the axle shaft or shafts that were removed.
  2.  
  3. Install the splash shield and spindle onto the steering knuckle. Install and tighten the spindle nuts to 40-50 ft. lbs.
  4.  
  5. Install the rotor on the spindle and push the outer wheel bearing inwards to seat it..
  6.  
  7. Install the locknuts and adjust the wheel bearings. Install the remainder of the locking hub assemblies.
  8.  

1998 B Series Pick-up
REAR WHEEL DRIVE

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the 1998 B Series Pick-up steering knuckle

The steering knuckle and spindle are an integral assembly.

  1. Position the steering wheel to the on-center position.
  2.  
  3. Loosen the wheel lug nuts then raise and safely support the front of the vehicle.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the front disc brake caliper, bracket and rotor. Also remove the rotor splash shield.
  8.  
  9. Remove the cotter pin and nut retaining the tie rod end to the steering knuckle.
  10.  
  11. Disconnect the tie rod end from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent.
  12.  
  13. If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
  14.  
  15. Support the lower control arm with a jack. Remove the cotter pin and loosen the nut retaining the lower ball joint to the steering knuckle.
  16.  
  17. Disconnect the lower ball joint from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent.
  18.  
  19. Remove the lower ball joint retaining nut and slowly raise the lower control arm until the ball joint stud is disengaged from the steering knuckle.
  20.  
  21. Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint from the knuckle.
  22.  
  23. Remove the steering knuckle/spindle assembly from the vehicle.
  24.  

To install:
  1. Inspect the upper and lower ball joints and seals for damage and replace as needed.
  2.  
  3. Position the steering knuckle onto the upper ball joint and install the retaining bolt and nut. Tighten the bolt to 30-41 ft. lbs. (40-55 Nm).
  4.  
  5. Install the lower ball joint stud into the steering knuckle until the stud protrudes through the knuckle.
  6.  
  7. Install the retaining nut to the lower ball joint stud and tighten to 84-113 ft. lbs. (113-153 Nm). Install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin.
  8.  
  9. Connect the tie rod end to the steering knuckle and install the retaining nut. Tighten to 57-77 ft. lbs. (77-104 Nm) and install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin.
  10.  
  11. Install the front disc brake splash shield, rotor, bracket and caliper.
  12.  
  13. Install the wheel and snug all of the lug nuts.
  14.  
  15. Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
  16.  

4-WHEEL DRIVE

WARNING
Do not perform this procedure unless a new wheel hub nut and washer assembly is available. Once removed, these parts must never be reused during assembly.

  1. Position the steering wheel to the on-center position.
  2.  


WARNING
If equipped, always turn off the Automatic Ride Control (ARC) service switch before lifting the vehicle off of the ground. Failure to do so could damage the ARC system components. Refer to General Information & Maintenance for jacking procedures.

  1. Loosen the wheel lug nuts then raise and safely support the front of the vehicle.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the front disc brake caliper, bracket and rotor. Also remove the rotor splash shield.
  6.  
  7. If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
  8.  
  9. Remove the front wheel hub nut and washer.
  10.  


WARNING
Never reuse the wheel hub nut and washer. This nut is a torque prevailing design and cannot be reused.

  1. Remove the cotter pin and nut retaining the tie rod end to the steering knuckle.
  2.  
  3. Disconnect the tie rod end from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent.
  4.  
  5. Unload the torsion bar. Follow the torsion bar removal procedures, but do not remove the bar.
  6.  
  7. Support the lower control arm with a jack. Remove the cotter pin and loosen the nut retaining the lower ball joint to the steering knuckle.
  8.  
  9. Disconnect the lower ball joint from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent.
  10.  
  11. Remove the lower ball joint retaining nut and slowly raise the lower control arm until the ball joint stud is disengaged from the steering knuckle.
  12.  

The hub shaft is a slip fit into the wheel hub and bearing; a press is not normally required.

  1. Ensure that the wheel hub shaft can be pushed inwards. If not, assemble a press to the front wheel studs and press the wheel hub shaft inwards slightly to break it loose.
  2.  
  3. Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint from the knuckle.
  4.  
  5. Remove the steering knuckle/spindle assembly from the vehicle.
  6.  

To install:
  1. Inspect the upper and lower ball joints and seals for damage and replace as needed.
  2.  
  3. Position the steering knuckle onto the upper ball joint, while aligning the axle shaft with the wheel hub, and install the retaining bolt and nut. Tighten the bolt to 30-41 ft. lbs. (40-55 Nm).
  4.  
  5. Install the lower ball joint stud into the steering knuckle until the stud protrudes through the knuckle.
  6.  
  7. Install the retaining nut to the lower ball joint stud and tighten to 84-113 ft. lbs. (113-153 Nm). Install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin.
  8.  
  9. Connect the tie rod end to the steering knuckle and install the retaining nut. Tighten to 57-77 ft. lbs. (77-104 Nm) and install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin.
  10.  
  11. If removed, install the ABS sensor to the wheel hub.
  12.  
  13. Install the hub washer and nut then tighten to 157-213 ft. lbs. (212-288 Nm).
  14.  
  15. Install the front disc brake splash shield, rotor, bracket and caliper.
  16.  
  17. Install the wheel and snug all of the lug nuts.
  18.  
  19. Reload the torsion bar pressure. Refer to the torsion bar installation procedures. Check and, if necessary, set the vehicle ride height.
  20.  
  21. Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
  22.  

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.  

 
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