Chrysler Pacifica. Manual — part 422
(14) Check and adjust brake fluid level as neces-
sary.
(15) Perform wheel alignment. (Refer to 2 - SUS-
PENSION/WHEEL
ALIGNMENT
-
STANDARD
PROCEDURE)
KNUCKLE
DESCRIPTION
The steering knuckle is a single aluminum cast-
ing with legs machined for attachment of the strut
assembly,
steering
linkage,
disc
brake
caliper
adapter, lower control arm ball joint and steering
linkage. The hub and bearing assembly is mounted
in the center of the steering knuckle using 4 bolts.
The driveshaft’s constant velocity (C/V) stub shaft is
splined through the center of the hub and bearing
and is held in place using a nut, nut lock and cotter
pin.
Service replacement of the front hub and bearing
assembly can be done with the steering knuckle
remaining on the vehicle.
REMOVAL
(1) Raise and support vehicle. (Refer to LUBRICA-
TION & MAINTENANCE/HOISTING - STANDARD
PROCEDURE)
(2) Remove wheel and tire assembly.
(3) Remove cotter pin, nut lock and spring washer
from end of halfshaft stub shaft and hub nut (Fig. 1).
(4) With aid of a helper applying brakes to keep
front hub from turning, remove hub nut (Fig. 1).
(5) Access and remove front brake rotor. (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -
REMOVAL)
(6) Disconnect vehicle wiring harness from wheel
speed sensor connector (Fig. 2).
(7) Unclip wheel speed sensor connector and rout-
ing clip from frame rail outer reinforcement (Fig. 2).
(8) Remove screw fastening wheel speed sensor
routing bracket to strut assembly (Fig. 3).
(9) Open routing clip at knuckle and remove wheel
speed sensor cable (Fig. 4).
(10) Push in on end of halfshaft stub shaft, push-
ing its splines out of hub splines.
(11) Remove nut attaching outer tie rod to steering
knuckle (Fig. 7) by holding outer tie rod stud station-
ary while loosening and removing nut with a wrench.
(12) Remove tie rod from steering knuckle using
Remover, Special Tool C-3894-A (Fig. 8).
(13) Remove two bolts attaching strut clevis to
steering knuckle (Fig. 9) (Fig. 10).
(14) Tip knuckle outward at top and remove half-
shaft stub shaft from hub and bearing. Suspend
driveshaft straight outward using a bungee cord or
wire. Do not allow driveshaft to hang by inner
joint.
(15) Remove ball joint nut using a power impact
wrench. Because tapered stud is held suffi-
ciently in knuckle at this time, it is not neces-
sary to hold stud stationary to remove nut.
Fig. 7 Tie Rod Attachment
1 - STEERING KNUCKLE
2 - JAM NUT (TIE ROD ADJUSTMENT)
3 - INNER TIE ROD SERRATIONS
4 - OUTER TIE ROD
5 - NUT
Fig. 8 Using C-3894-A To Release Tie Rod
1 - PULLER C-3894-A
2 - OUTER TIE ROD
3 - STEERING KNUCKLE
4 - TIE ROD STUD
CS
FRONT SUSPENSION
2 - 5
HUB / BEARING (Continued)
(16) Reinstall ball joint nut until top of nut is even
with top of ball joint stud. This action will keep
stud from distorting while stud is released from
knuckle in following step.
CAUTION: Do not remove ball joint stud from steer-
ing knuckle using a hammer. Damage to Aluminum
knuckle, ball joint or control arm will result.
NOTE: Lubricate Remover, Special Tool C-4150A,
screw-drive threads before use to ease use and
promote tool longevity.
(17) Place Remover, Special Tool C-4150A, over
ball joint stud and nut as shown (Fig. 11). Release
ball joint stud from steering knuckle by tightening
tool screw-drive. To ease Remover installation
and use, it may help to rotate knuckle around
so inside of knuckle faces outward.
(18) Remove tool and nut from top of ball joint
stud.
(19) Remove steering knuckle from vehicle.
(20) If hub and bearing needs to be transferred,
remove four bolts attaching hub and bearing to
knuckle, then remove hub and bearing.
INSPECTION
Inspect the knuckle for the following:
• Cracks or breaks
• Dents or damage
• Stress marks indicating a bend
The front suspension knuckle is not a repairable
component of the vehicles front suspension. If bent,
broken or damaged in any way, do not attempt to
Fig. 9 Left Side Correctly Oriented Mounting Bolts
1 - STRUT
2 - BOLT
3 - NUT
Fig. 10 Right Side Correctly Oriented Mounting
Bolts
1 - STRUT
2 - BOLT
3 - NUT
Fig. 11 Using C-4150A To Release Ball Joint
1 - ALUMINUM KNUCKLE
2 - SPECIAL TOOL C-4150A
3 - LOWER CONTROL ARM
4 - NUT INSTALLED ON BALL JOINT STEM
2 - 6
FRONT SUSPENSION
CS
KNUCKLE (Continued)
straighten or repair the steering knuckle. It must be
replaced.
If inspection leads to the hub and bearing, (Refer
to 2 - SUSPENSION/FRONT/HUB / BEARING -
DIAGNOSIS AND TESTING)
INSTALLATION
(1) If hub and bearing needs to be installed in
knuckle, place hub and bearing squarely into center
hole of knuckle with wheel speed sensor positioned
toward trailing end of knuckle. Align threaded
mounting holes of hub and bearing with mounting
holes in steering knuckle, then install four mounting
bolts. Progressively tighten mounting bolts in a criss-
cross pattern. Tighten mounting bolts to 65 N·m (45
ft. lbs.) torque.
CAUTION: Before installing knuckle on ball joint
stud, wipe ball joint stud and knuckle contact area
free of any grease or debris, otherwise damage to
knuckle can occur. Use a clean shop cloth with
Mopar
T
Brake Parts Cleaner applied to it for proper
cleaning. Do not spray stud directly.
(2) Place knuckle on ball joint stud.
(3) Install a NEW steering knuckle to ball joint
stud nut. Tighten nut by holding ball joint stud with
hex wrench while turning nut with a wrench (Fig.
12). Using a crowfoot wrench on a torque wrench,
tighten nut to 81 N·m (60 ft. lbs.) torque. Then,
tighten nut an additional 1/4 (90°) turn after that
torque is met.
(4) Slide halfshaft stub shaft into hub and bearing
assembly.
CAUTION: The steering knuckle to strut assembly
attaching bolts are serrated and must not be turned
during installation. Install nuts while holding bolts
stationary in steering knuckle.
CAUTION: If vehicle being serviced is equipped
with eccentric cam strut attaching bolts, eccentric
cam bolt must be installed in bottom (slotted) hole
on strut clevis bracket (Fig. 13).
NOTE: The strut clevis-to-steering knuckle bolts are
installed differently on each side. Left hand side
bolts are to be installed from vehicle rear to front
(Fig. 9). Right side bolts are to be installed from
vehicle front to rear (Fig. 10).
(5) Align steering knuckle in clevis bracket of
strut. Install strut clevis-to-steering knuckle attach-
ing bolts (Fig. 9) (Fig. 10). Install nuts on ends of
bolts and tighten to 81 N·m (60 ft. lbs.) torque. Then,
tighten nuts an additional 1/4 (90°) turn after that
torque is met.
CAUTION: Before installing tie rod stud in knuckle
steering arm, wipe stud and knuckle contact area
free of any grease or debris, otherwise damage to
knuckle can occur. Use a clean shop cloth with
Mopar
T
Brake Parts Cleaner applied to it for proper
cleaning. Do not spray stud directly.
(6) Install outer tie rod stud into knuckle steering
arm from bottom (Fig. 7). Start nut onto tie rod stud.
While holding stud stationary using a socket, tighten
nut using a wrench. Using a crowfoot wrench on a
torque wrench, tighten nut to 47 N·m (35 ft. lbs.)
Fig. 12 Ball Joint Nut Installation
1 - KNUCKLE
2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
Fig. 13 Package Bolts Correctly Installed (Left Side
Shown)
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
CS
FRONT SUSPENSION
2 - 7
KNUCKLE (Continued)
torque. Then, tighten nut an additional 1/2 (180°)
turn after that torque is met.
(7) Place wheel speed sensor cable grommet in clip
at knuckle (Fig. 4). Close clip.
(8) Attach wheel speed sensor routing bracket to
strut assembly (Fig. 3). Tighten screw to 13 N·m (115
in. lbs.) torque.
(9) Clip wheel speed sensor connector and routing
clip to frame rail outer reinforcement (Fig. 2).
(10) Connect vehicle wiring harness to wheel speed
sensor connector (Fig. 2).
(11) Install brake rotor, then install disc brake cal-
iper and adapter assembly. (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/ROTOR
-
INSTALLATION)
(12) Verify that wheel speed sensor is not routed
improperly allowing cable to come in contact with
brake rotor or other moving parts.
(13) Install washer and hub nut on end of half-
shaft stub shaft (Fig. 1). With aid of a helper apply-
ing brakes to keep front hub from turning, tighten
hub nut to 244 N·m (180 ft. lbs.) torque.
(14) Install spring washer and hub nut lock over
hub nut and stub shaft. Install a NEW cotter pin
securing nut lock in place and tightly wrap cotter pin
prongs around nut lock.
(15) Install tire and wheel assembly (Refer to 22 -
TIRES/WHEELS - INSTALLATION). Tighten wheel
mounting nuts to a torque of 135 N·m (100 ft. lbs.).
(16) Lower vehicle.
(17) Pump brake pedal several times to ensure
vehicle has a firm brake pedal before moving vehicle.
(18) Check and adjust brake fluid level as neces-
sary.
(19) Perform wheel alignment. (Refer to 2 - SUS-
PENSION/WHEEL
ALIGNMENT
-
STANDARD
PROCEDURE)
LOWER BALL JOINT
DIAGNOSIS AND TESTING - LOWER BALL
JOINT
With the weight of the vehicle resting on the road
wheels, grasp the special fitting cap on the bottom of
the ball joint and with no mechanical assistance or
added force, attempt to rotate the grease fitting.
If the ball joint is worn, the grease fitting will
rotate easily. If movement is noted, replacement of
the control arm is recommended.
LOWER BALL JOINT SEAL
BOOT
REMOVAL
(1) Remove steering knuckle from vehicle. (Refer
to
2
-
SUSPENSION/FRONT/KNUCKLE
-
REMOVAL)
(2) Using a screwdriver or other suitable tool, pry
seal boot off of ball joint (Fig. 14).
(3) Inspect ball joint for evidence of dirt or water
intrusion and wipe clean as necessary. If dirt or
water intrusion is extreme and joint cannot be prop-
erly cleaned, lower control arm will need to be
replaced.
(Refer
to
2
-
SUSPENSION/FRONT/
LOWER CONTROL ARM - REMOVAL)
INSTALLATION
(1) Place a liberal dab of Mopar
t Wheel Bearing
Grease (No more than 10g) around base of ball joint
stud at socket.
(2) Install a NEW seal boot by hand as far as pos-
sible on ball joint. Ensure seal boot shield is posi-
tioned outward from control arm as shown (Fig. 15).
CAUTION: Do not use an arbor press to install seal
boot on ball joint. Damage to seal boot will occur if
excessive pressure is applied while it is being
installed.
(3) Place Installer, Special Tool 6758, over top of
seal boot and squarely align it with bottom edge of
seal boot (Fig. 16). Apply hand pressure (or gently
Fig. 14 Ball Joint Seal Boot Removal
1 - BALL JOINT STUD
2 - SCREWDRIVER
3 - SEAL BOOT
2 - 8
FRONT SUSPENSION
CS
KNUCKLE (Continued)
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