This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2015 Kia Forte 1.8L, including disconnection of the brake caliper, rotor, wheel bearing, tie rod, ball joint, and strut.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Ball joint castle nut and cotter pin × 1 — Use OEM specification
• Tie rod end nut and cotter pin × 1 — Use OEM specification
• Axle nut (32mm) × 1 — Use OEM specification
• Front wheel bearing/hub assembly (if not reusing) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Loosen the 32mm axle nut while vehicle is on ground (have assistant apply brakes)
4. Raise vehicle and secure on jack stands at manufacturer jacking points
5. Remove front wheel completely
6. Spray all fasteners with penetrating oil and allow 10-15 minutes to soak

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper bracket bolts (14mm) from the rear of the knuckle. Remove the entire caliper and bracket assembly. Support the caliper with wire or a bungee cord to the strut spring to prevent stress on the brake hose. Do not disconnect the brake line. Slide the brake rotor off the hub.
2. 2

   Remove axle nut and disconnect ABS sensor
   Completely remove the 32mm axle nut that was previously loosened. Locate the ABS wheel speed sensor connector and disconnect it. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle to prevent damage.
3. 3

   Disconnect tie rod end from knuckle
   Remove the cotter pin and castle nut from the tie rod end stud. Use a tie rod end puller to separate the tie rod from the steering arm on the knuckle. Avoid using a hammer directly on the tie rod end threads as this can damage the threads. Count and record turns when removing tie rod end if reusing for alignment reference.
4. 4

   Disconnect lower ball joint from knuckle
   Remove the cotter pin from the lower ball joint castle nut. Remove the ball joint castle nut completely. Use a ball joint separator or pickle fork to break the taper between the ball joint stud and the knuckle. Apply pressure gradually to avoid sudden separation. Once separated, pull the knuckle upward to clear the ball joint stud.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
5. 5

   Disconnect strut from knuckle
   Locate the two strut-to-knuckle pinch bolts on the lower portion of the strut assembly (17mm). Remove both bolts completely. Note the orientation of any alignment marks or eccentric washers. Spread the knuckle clamp slightly with a pry bar if needed and slide the knuckle off the strut tube. Be prepared to support the knuckle weight.
   Torque spec

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

   Remove axle from hub and extract knuckle
   Push the axle shaft out of the hub bearing. You may need to tap it gently with a soft mallet from behind or use a puller if it is stuck. Once the axle is clear, maneuver the knuckle assembly out from the wheel well. If the axle is stuck in the hub, use a hub puller to avoid damaging the CV joint.
7. 7

   Transfer or replace wheel bearing/hub assembly
   If reusing the wheel bearing/hub, press it out of the old knuckle using a hydraulic press and appropriate adapters. Clean the hub bore in the new knuckle thoroughly. Press the bearing/hub into the new knuckle, ensuring it seats completely and squarely. If replacing as an assembly, install the new hub/bearing into the new knuckle per manufacturer specifications. Replace the hub mounting bolts if applicable.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
8. 8

   Install knuckle onto strut
   Guide the new knuckle assembly into position, aligning the axle shaft through the hub bearing first. Slide the knuckle onto the strut tube, aligning the pinch bolt holes. Align any eccentric washers or alignment marks noted during disassembly. Install both strut-to-knuckle bolts finger-tight initially. Torque both bolts to specification.
   Torque spec

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

   Connect lower ball joint to knuckle
   Position the knuckle over the lower ball joint stud. Install the new castle nut and torque to specification. Align the castle nut slots with the stud cotter pin hole. If slots don't align, tighten further (never loosen) until aligned. Install a new cotter pin and bend tabs securely.
   Torque spec

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

    Connect tie rod end to knuckle
    Insert the tie rod end stud into the steering arm hole on the knuckle. Install the new castle nut and torque to specification (typically 36-40 ft-lbs for tie rod, though not listed in your torque database). Align castle nut slots with the cotter pin hole and install a new cotter pin. Bend tabs securely. If you counted turns during removal, thread to the same position for rough alignment.
11. 11

    Install axle nut and ABS sensor
    Install the new 32mm axle nut onto the axle shaft threads. Torque to manufacturer specification (typically 177-199 ft-lbs for Kia Forte, though not listed in your database). Install the ABS wheel speed sensor into the knuckle bore and secure with mounting bolt. Reconnect the ABS sensor electrical connector.
12. 12

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub. Position the brake caliper bracket assembly over the rotor and align with the knuckle mounting holes. Install and torque the caliper bracket bolts to specification (typically 58-73 ft-lbs for Kia, though not listed in your database). Ensure the brake pads are properly seated.
13. 13

    Reinstall wheel and lower vehicle
    Mount the wheel onto the hub and install lug nuts hand-tight in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. After vehicle is lowered with full weight on suspension, torque the control arm bolts to specification if they were disturbed during the procedure
2. Pump the brake pedal several times until firm before moving the vehicle
3. Check brake fluid level and top off with DOT 4 if necessary
4. Test brake operation at low speed before driving normally

Verification

• Verify all fasteners are torqued to specification, especially critical suspension components
• Check that the ABS warning light is not illuminated after starting vehicle and test driving
• Test drive at low speed and verify no unusual noises, vibrations, or pulling
• Verify steering returns to center properly and no binding is present
• Schedule a professional wheel alignment as soon as possible, as tie rod position and strut angle may have changed
• After 50-100 miles, re-torque the axle nut and lug nuts to specification

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