Knuckle/Spindle - Front

Remove and replace the front wheel knuckle/spindle assembly on a 2005 Dodge Viper, including separation of the ball joint, tie rod, brake components, and strut-to-knuckle connection.

Warnings

Tools required

Parts

• Front wheel knuckle/spindle assembly × 1 — Use OEM specification
• Wheel hub and bearing assembly (if integrated) × 1 — Use OEM specification
• Ball joint castellated nut × 1 — Replace if damaged
• Tie rod end nut × 1 — Replace if damaged
• Cotter pins × 2 — Standard size

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
4. Remove front wheel and tire assembly completely
5. Spray penetrating oil on ball joint nut, tie rod end nut, and strut-to-knuckle bolts if corrosion is visible

Procedure

1. 1

   Remove brake caliper
   Remove the two brake caliper mounting bolts from the rear of the caliper bracket. Slide the caliper off the rotor and support it with wire or a zip tie attached to the strut spring or suspension component. Do not disconnect the brake hose. Ensure the caliper is supported and not hanging by the brake hose.
2. 2

   Remove brake rotor
   Remove the brake rotor from the hub. If the rotor is seized to the hub, strike it from behind with a dead blow hammer or thread bolts into the rotor's threaded holes (if present) to press it off. Clean any rust or debris from the hub face with a wire brush.
3. 3

   Disconnect ABS wheel speed sensor
   The 2005 Viper is not equipped with ABS; there is no front wheel speed sensor to disconnect on this vehicle. Skip this step if no sensor is present. Disconnect the electrical connector by releasing the locking tab. Remove the sensor mounting bolt from the knuckle and carefully pull the sensor from its bore in the knuckle. Do not damage the sensor tip or allow metal debris to contact it.
4. 4

   Remove tie rod end
   Remove the cotter pin from the tie rod end castle nut. Loosen and remove the castle nut from the tie rod end stud. Use a tie rod end separator or pickle fork to separate the tie rod end from the knuckle steering arm. Strike the separator firmly with a hammer to break the taper. Once separated, remove the tool and pull the tie rod end free from the knuckle.
5. 5

   Disconnect sway bar link
   Locate the sway bar end link connection to the lower control arm or strut. Hold the ball stud shaft with an Allen key to prevent rotation, then remove the retaining nut. Separate the end link from the control arm or strut. This provides clearance for knuckle removal.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
6. 6

   Separate lower ball joint
   Remove the cotter pin from the lower ball joint castle nut. Loosen but do not fully remove the castle nut, leaving it threaded on several turns. Position a ball joint separator or pickle fork between the lower control arm and the knuckle at the ball joint taper. Strike the separator to break the taper joint. Once the joint is loose, remove the castle nut completely and separate the knuckle from the ball joint stud.
   ⚠The knuckle will become free once the ball joint separates. Support the knuckle to prevent it from falling or damaging the CV axle boot.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove strut-to-knuckle bolts
   The 2005 Viper uses a short/long arm double-wishbone suspension, not a strut. Separate the upper ball joint from the knuckle: remove the cotter pin and loosen the upper ball joint castle nut, use a ball joint separator to break the taper, then remove the nut and free the knuckle from the upper control arm.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
8. 8

   Remove knuckle assembly
   With all fasteners disconnected, carefully slide the knuckle assembly off the CV axle shaft splines. If the hub is seized to the axle, use a soft mallet to tap the knuckle from behind while pulling outward. Avoid damaging the CV boot or axle threads. Once free, remove the knuckle completely from the vehicle. Inspect the CV boot for tears or damage during removal.
9. 9

   Transfer components to new knuckle
   Unbolt the bolt-on front hub and bearing assembly from the old knuckle and transfer it (or install a new hub assembly) onto the new knuckle per manufacturer specifications, torquing the hub retaining bolts to specification. Transfer the dust shield and any brackets if they are separate components. If the hub and bearing are integrated with the knuckle, proceed with the new assembly as a complete unit. Clean all mating surfaces and inspect for damage.
10. 10

    Install knuckle onto CV axle
    Align the new knuckle assembly with the CV axle shaft. Slide the hub bore fully onto the axle splines, ensuring the axle passes completely through the hub. Align the upper control arm ball joint stud with the hole in the knuckle. Do not force the knuckle; ensure proper spline alignment.
11. 11

    Install strut-to-knuckle bolts
    Insert the upper ball joint stud fully into the knuckle taper, install the castle nut and torque to specification, then install a new cotter pin and bend the ends to secure.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
12. 12

    Connect lower ball joint
    Raise the lower control arm to align the ball joint stud with the hole in the knuckle. Insert the stud fully into the knuckle taper. Install the castle nut and torque to specification. Install a new cotter pin through the castle nut and stud hole, bending the ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
13. 13

    Reconnect tie rod end
    Insert the tie rod end stud into the knuckle steering arm taper. Install the castle nut and torque to specification. Install a new cotter pin through the castle nut and stud, bending the ends securely. Ensure the tie rod end is fully seated in the taper.
14. 14

    Reconnect sway bar link
    Align the sway bar end link with the lower control arm or strut mounting point. Install the retaining nut while holding the ball stud shaft with an Allen key to prevent rotation. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
15. 15

    Install ABS wheel speed sensor
    Clean the sensor bore in the knuckle with brake cleaner and ensure no metal debris is present. Apply a thin coat of anti-seize to the sensor body (not the tip). Insert the sensor fully into the bore until it seats. Install the mounting bolt and tighten securely. Reconnect the electrical connector until it clicks into place.
16. 16

    Install brake rotor and caliper
    Clean the hub face and rotor mounting surface with brake cleaner. Install the brake rotor onto the hub, ensuring it seats flat. Remove the caliper from its support and slide it over the rotor. Install the two caliper mounting bolts and tighten to specification. Remove the wire or support used to hold the caliper.
17. 17

    Install wheel and lower vehicle
    Mount the wheel and tire assembly onto the hub. Install the lug nuts by hand, threading them fully. Tighten the lug nuts in a star pattern to snug them, but do not torque yet. Lower the vehicle until the tire contacts the ground but the suspension is not fully loaded. Torque the lug nuts in a star pattern to specification. Fully lower the vehicle and remove the jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Torque all fasteners to specification in the order presented in the steps
2. Install new cotter pins on all castle nuts and bend the ends to secure properly
3. Verify brake caliper mounting bolts are tight before test driving
4. Pump the brake pedal several times after installation to ensure proper caliper piston positioning before moving vehicle

Verification

• Verify all fasteners are torqued to specification and cotter pins are installed
• Spin the wheel by hand to ensure the hub rotates freely without binding or noise
• Check that the brake caliper is secure and the brake hose is not twisted or stretched
• Verify the ABS wheel speed sensor is properly seated and connector is locked
• Test drive at low speed and verify no unusual noises, vibrations, or steering pull
• Schedule four-wheel alignment immediately; steering geometry has been disturbed and alignment is required

More procedures for this vehicle