Wheel Knuckle

Removal & Installation

To Remove:

1. Remove the wheel hub and the torsion bar.

   CAUTION
   Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft.

2. Suspend the front axle shaft with wire.
3. Remove the cotter pin and tie-rod end castellated nut.
4. Using the pitman arm puller (#211-003), separate the tie-rod end from the front wheel knuckle.
5. Remove the cotter pin and lower ball joint castellated nut.
6. Using the pitman arm puller, separate the front wheel knuckle from the front suspension lower arm.

   Pitman Arm Puller (#211-003)

7. Remove the pinch bolt, nut and the front wheel knuckle.

   NOTE: The knuckle main seal should only be removed from the knuckle if it is damaged or failed the leak test. The main seal cannot be reused once it has been removed from the knuckle.

8. Use a drift and a hammer to remove the main seal from the knuckle.
9. Thoroughly clean the knuckle's main seal bore. Using the shop air supply, thoroughly flush the vacuum hose and the knuckle vacuum chambers.
10. Inspect the knuckle main seal bore for any damage, nicks, burrs or pitting.
11. Inspect the steel vacuum line for damage or corrosion. If the vacuum line is damaged or corroded, a new knuckle must be installed.

To Install:

1. Apply a light coating of Ford High Temperature Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1C198-A to the bore of the knuckle.
2. To install the main seal, put the main seal into the seal replacer/CV tester (special tool #205-399) and the seal depth set/vacuum test cap (special tool #205-400), then install the special tools onto the knuckle. Turn the bolt until the special tool seats against the knuckle.

   Install the main seal

3. Remove the special tools.

   CAUTION
   Apply at least 3 grams of grease to the sealing surface of the main seal. Failure to do so can cause premature failure of the main seal, resulting in damage to the axle shaft or wheel knuckle, or loss of four-wheel drive.

4. Apply a thick coating of Ford High Temperature Wheel Bearing Grease (#E8TZ-19590-A), or an equivalent, to the sealing surfaces of the main seal.
5. Install the upper arm into the front wheel knuckle and then install the pinch bolt and nut. Tighten to 41 ft-lb (55 Nm).
6. Put the axle halfshaft into the wheel knuckle bore.

   CAUTION
   Be careful that no dirt or foreign material is present on the axle main seal before or after applying grease to seal. Failure to do so will result in failure of the axle main seal causing a loss of vacuum sealing.

7. Apply a coating of Ford High Temperature Wheel Bearing Grease (#E8TZ-19590-A) onto the axle main seal before seating the axle shaft against the main seal.

   CAUTION
   Install the cotter pin into the lower ball joint from outboard to inboard. Failure to do this correctly will result in damage to the wheel and tire assembly.

8. To connect the front suspension lower arm to the front wheel knuckle, do the following:
   • Step 1: Position the lower ball joint into the front wheel knuckle.
   • Step 2: Install the castellated nut and a new cotter pin.
   • Step 3: Tighten to 98 ft-lb (133 Nm).
9. Install the tie-rod end castellated nut and a new cotter pin. Tighten to 52 ft-lb (70 Nm).
10. Install the torsion bar and the wheel hub.
11. Lower the vehicle.
12. Perform the wheel-end vacuum leak test.
13. Check the ride height and the alignment.