Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Steering Knuckle

Print

REMOVAL & INSTALLATION



See Figures 1 through 12

  1. If equipped with an Anti-lock Brake System (ABS), disconnect the negative battery cable.
  2.  
  3. Have an assistant depress the brake pedal and loosen the front halfshaft nut, then raise the front of the vehicle and support it safely using jackstands.
  4.  
  5. Remove the wheel assembly.
  6.  
  7. Remove the brake caliper mounting bracket bolts and suspend the assembly from the strut spring with mechanic' wire or a coat hanger. Make sure the brake line is positioned so that it is not under stress and is not damaged.
  8.  
  9. Loosen the strut-to-knuckle bolts, but do not remove at this time.
  10.  
  11. Remove the rotor; if difficulty is encountered, use two M8 x 1.25 self-tapping bolts in the provided holes to drive the rotor from the hub. Remove the axle nut and washer.
  12.  
  13. Remove and discard the cotter pin from the lower control arm ball joint stud. Back off the ball joint nut until the top of the nut is even with the top of the threads.
  14.  
  15. Use ball joint separator tool SA9132S or equivalent to separate the lower control arm from the steering knuckle, then remove the nut. Do not use a wedge tool or seal damage may occur.
  16.  


WARNING
The outer CV-joint for vehicles equipped with ABS contains a speed sensor ring. Use of an incorrect tool to separate the control arm from the knuckle may result in damage and loss of the ABS.

  1. Remove the tie rod cotter pin and castle nut, then separate the tie rod end from the knuckle, using tie rod separator SA91100C or equivalent. Do not use a wedge-type tool.
  2.  
  3. If equipped, unplug the ABS wheel speed sensor electrical connector.
  4.  
  5. Remove the strut-to-knuckle fasteners at this time.
  6.  
  7. Suspend the halfshaft from the body with wire, then remove the knuckle/hub fasteners and remove the knuckle/hub assembly from the vehicle.
  8.  
  9. If difficulty is encountered removing the knuckle, position a block of wood on the end of the halfshaft and tap on the wood with a hammer to free the hub assembly.
  10.  

To install:
  1. Thoroughly clean and lubricate the ball joint stud threads of the lower control arm and tie rod end.
  2.  
  3. Install the knuckle/hub assembly onto the axle shaft. Then, install the washer with a new nut, but do not tighten the nut at this time.
  4.  

A new nut must be used, because the torque retention of the old nut may not be sufficient.

  1. Install the lower control arm ball stud and install the nut, but do not tighten at this time.
  2.  
  3. Install the steering knuckle-to-strut fasteners, but do not tighten at this time.
  4.  
  5. Install the tie rod end and nut. Tighten the nut to 33 ft. lbs. (45 Nm) and install a new cotter pin. If necessary, tighten the nut additionally, but do not back it off to insert the cotter pin.
  6.  
  7. Push inward on the bottom of the strut and tighten the knuckle fasteners to 126 ft. lbs. (170 Nm).
  8.  
  9. Tighten the lower control arm ball stud nut to 55 ft. lbs. (75 Nm); tighten additionally only as necessary to install a new cotter pin.
  10.  
  11. Install the rotor onto the hub and the caliper mount bracket onto the knuckle. Tighten the mount bracket assembly bolts to 81 ft. lbs. (110 Nm).
  12.  
  13. If equipped, engage the ABS electrical connector to the wheel speed sensor.
  14.  
  15. Have an assistant depress the brake pedal and tighten the halfshaft nut to 148 ft. lbs. (200 Nm).
  16.  
  17. Install the wheel assembly, remove the supports and lower the vehicle.
  18.  
  19. Connect the negative battery cable. Check and adjust the front end alignment, as necessary.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: With the wheels on the ground and the brakes applied, loosen the halfshaft nut



Click image to see an enlarged view

Fig. Fig. 2: Remove the brake caliper and mounting bracket from the knuckle, and suspend the assembly from the strut spring with a wire or coat hanger



Click image to see an enlarged view

Fig. Fig. 3: After removing the brake rotor, remove the axle nut and washer



Click image to see an enlarged view

Fig. Fig. 4: Remove and discard the cotter pin from the lower control arm ball joint stud



Click image to see an enlarged view

Fig. Fig. 5: Back off the ball joint nut until the top of the nut is even with the top of the threads



Click image to see an enlarged view

Fig. Fig. 6: Break the lower control arm loose from the steering knuckle using a ball joint separator tool ...



Click image to see an enlarged view

Fig. Fig. 7: ... then remove the retaining nut from the ball joint stud



Click image to see an enlarged view

Fig. Fig. 8: Remove and discard the tie rod end's cotter pin ...



Click image to see an enlarged view

Fig. Fig. 9: ... then, after loosening the castle nut with a wrench, remove it from the tie rod end ball stud



Click image to see an enlarged view

Fig. Fig. 10: Remove the strut-to-steering knuckle bolts



Click image to see an enlarged view

Fig. Fig. 11: Tie the halfshaft to the body with wire, then remove the steering knuckle assembly from the vehicle



Click image to see an enlarged view

Fig. Fig. 12: A hammer can be used to separate the halfshaft and the knuckle, but ONLY if a block of wood is positioned to protect components

 
label.common.footer.alt.autozoneLogo