Complete removal and replacement of the front steering knuckle/spindle assembly, including disconnection of the brake caliper, rotor, wheel speed sensor, tie rod, ball joint, and strut.

Warnings

Tools required

Parts

• Front steering knuckle/spindle assembly × 1 — Use OEM specification
• Front wheel hub bearing (if integrated) × 1 — Use OEM specification
• Ball joint castle nut (new) × 1 — Use OEM specification
• Tie rod end castle nut (new) × 1 — Use OEM specification
• Axle nut (new, single-use) × 1 — Use OEM specification

Fluids

• DOT 3 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground (do not remove)
3. Loosen but do not remove the 32mm axle nut while vehicle is on ground with brakes applied
4. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
5. Remove wheel and tire assembly
6. Apply rust penetrant to ball joint nut, tie rod nut, and strut pinch bolts if corrosion is present

Procedure

1. 1

   Remove axle nut and brake components
   Completely remove the 32mm axle nut that was previously loosened. Remove the brake caliper mounting bolts (use 12mm or 14mm socket) and support the caliper with wire or bungee cord WITHOUT letting it hang by the brake hose. Do not disconnect the brake line at this time. Remove the brake rotor by pulling it off the hub (may require light tapping if stuck).
2. 2

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor on the back of the knuckle. Disconnect the electrical connector by pressing the release tab. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle. Set aside to avoid damage.
3. 3

   Remove tie rod end from knuckle
   Remove the cotter pin from the tie rod end castle nut. Loosen the castle nut but leave it threaded on a few turns to protect the threads. Use a tie rod end puller or pickle fork to separate the tie rod from the knuckle steering arm. Once separated, remove the castle nut completely and remove the tie rod end from the knuckle.
4. 4

   Separate lower ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Loosen the castle nut but leave it threaded on a few turns. Use a ball joint separator or pickle fork to break the taper between the ball joint stud and knuckle. Once separated, remove the castle nut completely. The lower control arm will now drop away from the knuckle.
5. 5

   Remove strut-to-knuckle pinch bolts
   Locate the two pinch bolts that clamp the knuckle to the strut. These are typically 17mm bolts. Remove both bolts completely. You may need to spread the pinch joint slightly with a pry bar or tap the knuckle to separate it from the strut.
   Torque spec

   Strut Bolts109 Nm (81 lb-ft)
6. 6

   Remove knuckle and axle shaft
   Pull the knuckle assembly away from the strut while simultaneously pulling the axle shaft out of the wheel hub. You may need to tap the end of the axle shaft with a brass hammer or use a hub puller if the shaft is stuck in the bearing. Once the axle is free from the hub, maneuver the knuckle assembly out of the wheel well. Support the axle shaft with wire to prevent it from hanging and damaging the CV boot or inner joint.
7. 7

   Transfer components to new knuckle (if applicable)
   If the new knuckle does not come with the wheel hub bearing assembly pre-installed, you will need to press out the old bearing and press in the new one using a hydraulic press and proper bearing drivers. Also transfer the brake dust shield if it is not included with the new knuckle. Ensure all mounting surfaces are clean and free of corrosion.
8. 8

   Install knuckle onto strut
   Guide the axle shaft through the new knuckle hub bearing while positioning the knuckle onto the strut. Align the pinch joint and insert both strut-to-knuckle bolts. Thread the bolts by hand first to ensure proper alignment, then torque to specification. Ensure the pinch joint gap is uniform.
   Torque spec

   Strut Bolts109 Nm (81 lb-ft)
9. 9

   Reconnect lower ball joint
   Lift the lower control arm and insert the ball joint stud into the knuckle. Install the new castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure. If the cotter pin hole does not align, tighten the nut slightly more (never loosen to align).
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
10. 10

    Reconnect tie rod end
    Insert the tie rod end stud into the knuckle steering arm. Install the new castle nut and torque to specification. Install a new cotter pin and bend the ends to secure. Verify the tie rod boot is not torn or twisted.
11. 11

    Reinstall wheel speed sensor
    Clean the wheel speed sensor bore in the knuckle with a clean cloth. Apply a thin coating of anti-seize to the sensor body (not the tip). Insert the sensor into the knuckle and install the mounting bolt. Reconnect the electrical connector and ensure the wire is properly routed and secured with any clips.
12. 12

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub. Position the brake caliper and bracket over the rotor and install the caliper mounting bolts. Torque the caliper mounting bolts to specification. Pump the brake pedal several times to seat the brake pads against the rotor.
13. 13

    Install new axle nut
    Install the new 32mm axle nut onto the axle shaft and thread it by hand. Do not fully torque at this time - it will be torqued after the vehicle is lowered with the brakes applied. Snug the nut to prevent the axle from backing out.
14. 14

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread the lug nuts by hand, then snug them in a star pattern. Lower the vehicle until the tire just contacts the ground but the full weight is not on the suspension. Torque the lug nuts to specification in a star pattern. Lower the vehicle completely to the ground.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)
15. 15

    Final torque axle nut
    With the vehicle on the ground, have an assistant apply the brakes firmly. Torque the 32mm axle nut to 242 Nm (181 lb-ft). Stake the axle nut into the axle shaft groove using a punch and hammer, or install the cotter pin if applicable to your specific axle design.

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify the axle nut is properly staked or pinned to prevent loosening
3. Check that the brake caliper is securely mounted and brake hose is not kinked or twisted
4. Confirm all electrical connectors for the wheel speed sensor are fully seated

Verification

• Pump the brake pedal several times to ensure firm pedal feel before driving
• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the wheel bearing or suspension
• Check for proper steering feel and verify the wheel returns to center after turns
• Inspect for any brake fluid leaks around the caliper and brake lines
• Have the front end alignment checked and adjusted by a qualified technician - knuckle replacement will alter alignment settings
• Verify the ABS warning light does not illuminate (wheel speed sensor functioning properly)

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