Steering Knuckle and King Pin Replacement Conventional Wheel Ends

Special Tools

J 8001 Dial Indicator Set

1. Set the parking brake.
2. Block the vehicle rear wheels.
3. Raise the front of the vehicle until the tires clear the floor.
4. Support the frame using suitable safety stands.
5. Remove the tire and wheel assemblies as needed. Refer to Tire and Wheel Removal and Installation.
6. Remove the hub cap assemblies as needed. Refer to Hub Cap Replacement.
7. Remove the hub and bearing assemblies. Refer to Front Wheel Hub, Bearing, and Seal Replacement.
8. Remove the tie rod arms as needed. Refer to Tie Rod Arm Replacement.
9. Remove the steering arms as needed. Refer to Steering Arm Replacement.



10. Remove the cap screws that fasten the king pin caps (1) to the top and bottom of the knuckle (2).




Note: Do not use heat on any parts or fasteners.

11. Remove the nut (1) from the draw key (2).



12. Remove the draw key from the axle using a hammer and a brass drift.



13. Remove the king pin (1) by knocking out with a hammer and a brass drift if needed.



14. Remove the steering knuckle (1).
15. Remove the following components from the knuckle:

•	The shims (2)

•	The thrust bearing and seal (3)

16. Discard the thrust bearing (3).

1. Clean the axle components using a cleaning solvent.
2. Inspect the axle components for the following conditions:

•

Wear

•

Pitting

•

Cracks

•

Damage

3. Use Magna-Flux™ inspection, if available, in order to inspect the steering knuckle (14) and the kingpins (13) for minute cracks, checks, or fractures.
4. Inspect the axle king pin (13) bores for the following conditions:

•

Scratches

•

Burrs

•

Corrosion

5. Inspect the king pin bushing bores for the following conditions:

•

Scratches

•

Burrs

•

Corrosion

6. Smooth the bore using a crocus cloth or a fine grit sandpaper if needed. Clean the bore.

1. Install the knuckle (1) to the axle.
2. Install the king pin shims (2) and new thrust bearing and seal (3).



3. Lightly lubricate the following components:

•	The thrust bearing areas of the steering knuckle (3)

•	The axle end

•	The knuckle pin bore of the axle beam (1)

•	Pack the bushing bores with grease.




4. Install the knuckle to the axle beam.
5. Install pin (1) in knuckle and axle from the top.
6. Align the flat of the knuckle pin with the draw key hole.
7. Check knuckle vertical play and adjust.



8. Check knuckle vertical play using a dial indicator. Reference dial indicator at top of knuckle pin.



9. Simulate axle loading with a jack and note dial indicator reading.

Measure
Knuckle vertical play should be 0.015-0.305 mm (0.002-0.012 in).

10. Add or remove shims as necessary to obtain correct vertical end play.



11. Install a new draw key.
12. Align the draw key hole with the knuckle pin flat.

Caution: Refer to Fastener Caution in the Preface section.




13. Install the draw key nut (2).

Tighten
Tighten the nut to 50 N·m (37 lb ft).

Note: Do not apply excessive silicone compound which could block the grease path for the knuckle pin bushings.

14. Apply silicone rubber gasket compound to knuckle (2) cap mounting surface.



15. Install the knuckle king pin caps (1).
16. Install the cap bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

17. Install the steering arms as needed. Refer to Steering Arm Replacement.
18. Install the tie rod arms as needed. Refer to Tie Rod Arm Replacement.
19. Install the hub and bearing assemblies. Refer to Front Wheel Hub, Bearing, and Seal Replacement.
20. Install the hub cap assemblies as needed. Refer to Hub Cap Replacement.
21. Install the tire and wheel assemblies as needed. Refer to Tire and Wheel Removal and Installation.
22. Remove the safety stands and lower the vehicle.
23. Check the axle alignment.
24. Check the stop screw adjustment. Adjust as needed.

Stop Screw Adjustment
Adjust the steering stops so that the power assist stops approximately 3 degrees or 3.175 mm (1/8 in) before reaching the steering stop screws.

Steering Knuckle and King Pin Replacement Unitized Wheel Ends

Special Tools

J 8001 Dial Indicator Set

1. Set the parking brake.
2. Block the vehicle rear wheels. Refer to Lifting and Jacking the Vehicle.
3. Raise the front of the vehicle until the tires clear the floor.
4. Support the frame using suitable safety stands.
5. Remove the tire and wheel assemblies as needed. Refer to Tire and Wheel Removal and Installation.
6. Remove the hub cap assemblies as needed. Refer to Hub Cap Replacement.
7. Remove the hub and bearing assemblies. Refer to Front Wheel Hub, Bearing, and Seal Replacement.
8. Remove the tie rod arms as needed. Refer to Tie Rod Arm Replacement.
9. Remove the steering arms as needed. Refer to Steering Arm Replacement.



10. Remove the king pin caps (1) from the top and bottom of the knuckle.

Note: Do not use heat on any parts or fasteners.

11. Remove the draw key as follows:



12. Remove nut (2) from the draw key (1).



13. Remove the draw key from the axle using a hammer and a brass drift.



14. Remove the king pin (2) by knocking out with a hammer and a brass drift (1) if needed.



15. Remove the following components from the knuckle:

•	The shims (2)

•	The thrust bearing and seal (3)

16. Discard the thrust bearing (3).



17. Remove the knuckle (1) assembly.

1. Clean the axle components using a cleaning solvent.
2. Inspect the axle components for the following conditions:

•

Wear

•

Pitting

•

Cracks

•

Damage

3. Use Magna-Flux™ inspection, if available, in order to inspect the steering knuckle (14) and the kingpins (13) for minute cracks, checks, or fractures.
4. Inspect the axle king pin (13) bores for the following conditions:

•

Scratches

•

Burrs

•

Corrosion

5. Inspect the king pin bushing bores for the following conditions:

•

Scratches

•

Burrs

•

Corrosion

6. Smooth the bore using a crocus cloth or a fine grit sandpaper if needed. Clean the bore.

1. Install the knuckle (1) to the axle.
2. Install the king pin shims (2) and new thrust bearing and seal (3).



3. Lightly lubricate the following components:

•	The thrust bearing areas of the steering knuckle

•	The axle end

•	The knuckle pin bore of the axle beam

•	Pack the bushing bores with grease.




4. Install the knuckle to the axle beam.
5. Install the pin (2) in the knuckle and the axle from the top.
6. Align the flat of the knuckle pin with the draw key hole.
7. Check the knuckle vertical play and adjust.



8. Check the knuckle vertical play using a dial indicator. Reference the dial indicator at the top of the knuckle pin.



9. Simulate axle loading with a jack and note the dial indicator reading.

Measure
Knuckle vertical play should be 0.015-0.305 mm (0.002-0.012 in).

10. Add or remove shims as necessary to obtain correct vertical end play.



11. Install a new draw key.
12. Align the draw key hole with the knuckle pin flat.

Caution: Refer to Fastener Caution in the Preface section.




13. Install draw key nut (2).

Tighten
Tighten the nut to 50 N·m (37 lb ft).

Note: Do not apply excessive silicone compound which could block the grease path for the knuckle pin bushings.

14. Apply silicone rubber gasket compound to knuckle cap mounting surface.



15. Install the knuckle king pin caps (1).
16. Install the cap bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

17. Install the steering arms as needed. Refer to Steering Arm Replacement.
18. Install the tie rod arms as needed. Refer to Tie Rod Arm Replacement.
19. Install the hub and bearing assemblies. Refer to Front Wheel Hub, Bearing, and Seal Replacement.
20. Install the hub cap assemblies as needed. Refer to Hub Cap Replacement.
21. Install the tire and wheel assemblies as needed. Refer to Tire and Wheel Removal and Installation.
22. Remove the safety stands and lower the vehicle.
23. Check the axle alignment.
24. Check the stop screw adjustment. Adjust as needed.

Stop Screw Adjustment
Adjust the steering stops so that the power assist stops approximately 3 degrees or 3.175 mm (1/8 in) before reaching the steering stop screws.