Front Knuckle/Hub/Wheel Bearing Replacement

Special Tools Required
Hub dis/assembly tool, 42 mm ( 07GAF-SD40100)

Ball joint remover, 28 mm ( 07MAC-SL00200)

Attachment, 72 x 75 mm ( 07746-0010600)

Attachment, 78 x 90 mm ( 07GAD-SD40101)

Driver, ( 07749-0010000)

Support base, ( 07965-SD90100)

Knuckle/Hub Replacement

1.	Raise the front of the vehicle, and support it with safety stands in the proper locations.

2.	Remove the wheel nuts, and front wheel.

3.	Remove the brake hose mounting bracket (A).

4.	Remove the brake caliper bracket mounting bolts (B), and remove the caliper assembly (C) from the knuckle. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose with force.

5.	Remove the wheel sensor (A) from the knuckle. Do not disconnect the wheel sensor connector.

6.	Raise the stake (A), and remove the spindle nut (B).

7.	Remove the 6 mm brake disc retaining screws (A).

8.	Screw two 8X1.25 mm bolts (B) into the disc to push it away from the hub. Turn each bolt two turns at a time to prevent cocking the disc excessively.

9.	Remove the brake disc (C) from the knuckle.

10.	Remove the cotter pin (A) from the tie-rod end ball joint, and loosen the nut (B). NOTE: During installation, install the new cotter pin after tightening the nut, and bend its end as shown.

11.	Disconnect the tie-rod end ball joint from the knuckle using the special tool.

12.

Remove the cotter pin (A) from the lower arm ball joint, and loosen the nut (B)

NOTE:

Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint.
Insert the new cotter pin in to the ball joint pin from the forward to the rearward of the vehicle, and bend its end as shown.

13.	Disconnect the lower arm ball joint from the lower arm using the special tool.

14.	Remove the cotter pin (A) from the upper arm ball joint, and loosen the nut (B). NOTE: During installation, insert the new cotter pin into the ball joint pin from the forward to the rearward of the vehicle, and bend its end as shown.

15.	Disconnect the upper arm ball joint from the knuckle using the special tool.

16.	Remove the driveshaft outboard joint (A) from the knuckle (B) by tapping the driveshaft end (C) with a plastic hammer while drawing the hub outward, then remove the knuckle. NOTE: Do not pull the driveshaft end outward. The inner driveshaft joint may come apart.

17.

Install the knuckle/hub in the reverse order of removal, and note these items:

Be careful not to damage the ball joint boot when installing the knuckle.
Tighten all mounting hardware to the specified torque values.
Before connecting the lower arm ball joint to the lower arm, degrease the threaded section and tapered portion of the ball joint pin, and the lower arm connecting hole, and the threaded section and mating surface of the castle nut.
First install all the components and lightly tighten the bolts and nuts, then raise the suspension to load it with the vehicle's weight before fully tightening to the specified torques. Do not place the jack against the ball joint pin of the knuckle.
Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it.
Install a new cotter pin on the castle nut after torquing.
Use a new spindle nut on reassembly.
Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft.
Replace the self-locking nuts with new ones.
Before installing the brake disc, clean the mating surface of the front hub and the inside of the brake disc.
Before installing the wheel, clean the mating surface of the brake disc and the inside of the wheel.
Check the front wheel alignment, and adjust it if necessary.

1.	Separate the hub (A) from the knuckle (B) using the special tool and a hydraulic press. Hold the knuckle with the attachment (C) of the hydraulic press or equivalent tool. Be careful not to deform the splash guard. Hold onto the hub to keep it from falling when pressed clear.

2.	Press the wheel bearing inner race (A) off of the hub (B) using the special tool, a commercially available bearing separator (C), and a press.

3.	Remove the snap ring (A) and the splash guard (B) from the knuckle (C).

4.	Check the front knuckle ring (A) for damage or deformation, and replace it if necessary.

5.	Press the wheel bearing (A) out of the knuckle (B) using the special tool and a press.

6.	Wash the knuckle and hub thoroughly in high flash point solvent before reassembly.

Press a new wheel bearing (A) into the knuckle (B) using the old bearing (C), a steel plate (D), the special tool, and a press.

NOTE:

Install the wheel bearing with the wheel sensor magnetic encoder (E) (brown color), toward the inside of the knuckle.
Remove any oil, grease, dust, and other foreign material from the encoder surface.
Keep any magnetic tools away from the encoder surface.
Be careful not to damage the encoder surface when you insert the wheel bearing.

8.	Install the new front knuckle ring (A) on the inside of the knuckle by aligning the cutout portion (B) on the ring with the wheel sensor hole (C) in the knuckle. Be careful not to damage or deform the ring when installing it.

9.	Install the snap ring (A) securely in the knuckle (B).

10.	Install the splash guard (C), and tighten the screws (D) to the specified torque.

11.	Press a wheel bearing (A) onto the hub (B) using the special tools and a press.