Knuckle/Spindle - Front

Remove and replace the front knuckle/spindle assembly including disconnecting the ball joint, strut, tie rod, control arm, brake caliper, wheel speed sensor, and hub bearing.

Warnings

Tools required

Parts

• Front knuckle/spindle assembly × 1 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification
• Hub bearing assembly (if not included with knuckle) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands under frame rails
5. Remove front wheel on side being serviced
6. Spray all fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully lift the caliper off the rotor. Support the caliper with wire or a bungee cord to avoid tension on the brake hose. Do not disconnect the brake hose. Remove the brake rotor by pulling it off the hub studs.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
2. 2

   Disconnect wheel speed sensor
   Locate the ABS wheel speed sensor on the back of the knuckle. Disconnect the electrical connector and remove the mounting bolt securing the sensor to the knuckle. Carefully remove the sensor from the knuckle bore to prevent damage.
3. 3

   Remove sway bar link
   Locate the sway bar end link connection at the lower control arm. Use an Allen key to hold the shaft while removing the upper nut connecting the link to the control arm. If the ball joint spins, use penetrating oil and hold firmly.
   Torque spec

   Sway Bar Link64 Nm (47 lb-ft)
4. 4

   Disconnect tie rod end
   Remove the castle nut securing the tie rod end to the knuckle. Remove the cotter pin first if present. Use a tie rod end puller to separate the tie rod end taper from the knuckle bore. Do not use excessive force or strike the knuckle directly as this may damage the casting.
5. 5

   Disconnect lower ball joint
   Remove the castle nut from the lower ball joint stud at the bottom of the knuckle. Extract and discard the cotter pin. Use a ball joint separator or pickle fork to break the taper loose from the knuckle. Pry downward on the control arm to fully separate once the taper is broken.
   Torque spec

   Ball Joint Nut92 Nm (68 lb-ft)
6. 6

   Remove strut-to-knuckle bolts
   Support the knuckle assembly with one hand or a jack. Remove the two large bolts connecting the strut to the top of the knuckle. These are high-torque fasteners and may require a breaker bar. Once removed, the knuckle will be free to pivot downward.
   ⚠Knuckle assembly is heavy and will drop once strut bolts are removed. Support it before removing the second bolt.
   Torque spec

   Strut Bolts121 Nm (89 lb-ft)
7. 7

   Remove knuckle and hub assembly
   Carefully maneuver the knuckle assembly out from the wheel well. The hub and bearing are typically pressed into the knuckle and may come as an assembly. If reusing the hub bearing, it will need to be pressed out of the old knuckle and into the new one at a machine shop. Inspect all mounting surfaces for damage or corrosion.
8. 8

   Install new knuckle assembly
   If the hub bearing was removed, ensure it is properly pressed into the new knuckle with the correct orientation before installation. Apply anti-seize to all mounting surfaces and fastener threads. Position the new knuckle assembly into the wheel well and align the strut mounting holes.
9. 9

   Connect strut to knuckle
   Install the two strut-to-knuckle bolts and hand-tighten. Ensure the knuckle is properly seated against the strut bracket before tightening. Torque the bolts to specification using a calibrated torque wrench.
   Torque spec

   Strut Bolts121 Nm (89 lb-ft)
10. 10

    Connect lower ball joint
    Position the lower control arm ball joint into the knuckle bore. Install the castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, ensuring it is properly spread to prevent loosening.
    Torque spec

    Ball Joint Nut92 Nm (68 lb-ft)
11. 11

    Reconnect tie rod end
    Insert the tie rod end taper into the knuckle bore. Install the castle nut and torque to specification. Install a new cotter pin if the design uses one. Ensure the taper is fully seated before final tightening.
12. 12

    Install sway bar link
    Connect the sway bar end link to the lower control arm. Hold the shaft with an Allen key and install the nut. Torque to specification while preventing the ball stud from spinning.
    Torque spec

    Sway Bar Link64 Nm (47 lb-ft)
13. 13

    Install wheel speed sensor and brake components
    Install the ABS wheel speed sensor into the knuckle bore and torque the mounting bolt to specification. Reconnect the electrical connector. Install the brake rotor onto the hub studs. Position the brake caliper over the rotor and install the mounting bolts, torquing to specification.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)
14. 14

    Install wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire contacts the ground but suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern. Fully lower the vehicle.
    Torque spec

    Wheel Lug Nuts142 Nm (105 lb-ft)

Reassembly

1. After vehicle is on the ground with full weight on suspension, final-torque the control arm bolts to specification if they were removed or loosened during the procedure
2. Pump brake pedal several times to ensure proper caliper piston position before attempting to move vehicle
3. Verify all fasteners are tightened to specification and no tools or parts are left in the wheel well

Verification

• Test drive vehicle at low speed in a safe area and verify no unusual noises or vibrations from the front suspension
• Check for proper steering response and ensure the wheel speed sensor is functioning (no ABS warning light)
• Re-torque wheel lug nuts after 50-100 miles of driving
• Have front wheel alignment performed immediately as suspension geometry has been disturbed

More procedures for this vehicle