Steering Knuckle Replacement (4WD with Z56)

Single Use Fasteners and Components Front Wheel Drive Shaft Nut Front Wheel Hub Bolt [4x] Front Wheel Hub Seal [2x] Special Tools Disc Brakes CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit Equivalent regional tools: Special Tools Driveline DT-45859 Axle Remover Equivalent regional tools: Special Tools. Suspension CH-43631 Ball Joint Separator CH-42188–B Ball Joint Separator Equivalent regional tools: Special Tools

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

Brake Dust Warning Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle
3. Remove the front tire and wheel assembly. Tire and Wheel Removal and Installation
4. Have an assistant apply the brakes.

Steering Knuckle Replacement (4WD with Z56) — figure 1

Caution

DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

5. Front Wheel Drive Shaft Nut (1) » Remove and DISCARD

Steering Knuckle Replacement (4WD with Z56) — figure 2

6. Install the DT-45859 Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
7. Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
8. Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.

Steering Knuckle Replacement (4WD with Z56) — figure 3

9. Front Brake Hose Bracket Bolt (1) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 4

10. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 5

11. { If equipped } Front Wheel Speed Sensor Bracket Bolt (1) » Remove
12. { If equipped } Front Wheel Speed Sensor Bracket (2) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 6

13. Front Brake Caliper Bolt (2) » Remove [2x]

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

14. Remove the brake caliper and support with heavy mechanics wire. (1)

Steering Knuckle Replacement (4WD with Z56) — figure 7

15. Front Brake Rotor Bolt (1) » Remove
16. Front Brake Rotor (2) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 8

17. Front Wheel Speed Sensor Bolt (4) » Remove
18. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
19. Front Wheel Speed Sensor (3) » Remove
20. Front Wheel Speed Sensor Bracket (2) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 9

21. Front Wheel Speed Sensor Bracket Bolt (1) » Remove
22. Remove the front wheel speed sensor wiring harness bracket (2).

Steering Knuckle Replacement (4WD with Z56) — figure 10

23. Steering Linkage Outer Tie Rod Nut (1) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 11

Caution

Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.

24. Using CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.

Steering Knuckle Replacement (4WD with Z56) — figure 12

25. Reposition the front wheel drive half shaft as necessary to access the front wheel hub bolts (1).
26. Front Wheel Hub Bolt (1) » Remove and DISCARD [4x]

Steering Knuckle Replacement (4WD with Z56) — figure 13

27. Front Wheel Hub (1) » Remove
28. Front Brake Shield (2) » Remove
29. Front Wheel Hub Seal (3) » Remove and DISCARD [2x]

Note

Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.

30. Support the lower control arm with a suitable jack stand.

Steering Knuckle Replacement (4WD with Z56) — figure 14

31. Front Stabilizer Shaft Link Nut (2) » Remove [2x]
32. Front Stabilizer Shaft Link (1) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 15

33. Front Upper Control Arm Ball Stud Nut (1) » Loosen

Steering Knuckle Replacement (4WD with Z56) — figure 16

34. Using the CH-42188–B Ball Joint Separator(1) , separate the left front upper control arm (2) from the steering knuckle.
35. Remove the CH-42188–B Ball Joint Separator(1) from the left front upper control arm (2) and the steering knuckle.

Steering Knuckle Replacement (4WD with Z56) — figure 17

36. Front Upper Control Arm Ball Stud Nut (1) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 18

37. Front Lower Control Arm Ball Stud Nut (1) » Remove

Steering Knuckle Replacement (4WD with Z56) — figure 19

38. Front Lower Control Arm (1) @ Steering Knuckle (2) » Release —  use CH-43631 Ball Joint Separator(3)

Steering Knuckle Replacement (4WD with Z56) — figure 20

39. Steering Knuckle (1) » Remove Installation Procedure

40. Steering Knuckle (1) » Install

41. Support the steering knuckle with a suitable jack stand.

Caution

Refer to Fastener Caution.

3. Front Lower Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

4. Front Upper Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

5. Front Stabilizer Shaft Link (1) » Install

6. Front Stabilizer Shaft Link Nut (2) » Install and tighten [2x] — Fastener Specifications

7. Clean any debris and corrosion from the steering knuckle bearing pilot bore.

8. Apply a thin coating of grease evenly ensuring complete coverage of the steering knuckle pilot bore only. Adhesives, Fluids, Lubricants, and Sealers

Note

Ensure that the front wheel hub seals are properly seated in the grooves of the steering knuckle.

9. Front Wheel Hub Seal (3) » Install NEW [2x]

10. Front Brake Shield (2) » Install

11. Front Wheel Hub (1) » Install

12. Reposition the front wheel drive half shaft as necessary to install the front wheel hub bolts (1).

13. Front Wheel Hub Bolt (1) » Install NEW and tighten [4x] — Fastener Specifications

14. Steering Linkage Outer Tie Rod Nut (1) » Install and tighten — Fastener Specifications

15. Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

16. Install the front wheel speed sensor wiring harness bracket (2).

17. Front Wheel Speed Sensor Bracket (2) » Install

18. Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

19. Front Wheel Speed Sensor (3) » Install

20. Front Wheel Speed Sensor Bolt (4) » Install and tighten — Fastener Specifications

Note

Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminates should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

21. Using the CH-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.

22. Using the CH-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.

23. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure there are no foreign particles or debris remaining.

24. Front Brake Rotor (2) » Install

25. Front Brake Rotor Bolt (1) » Install and tighten — Fastener Specifications

26. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 26.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 26.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 26.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 26.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

27. Front Brake Caliper (1) » Install

28. Front Brake Caliper Bolt (2) » Install and tighten [2x] — Fastener Specifications

29. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

30. { If equipped } Front Wheel Speed Sensor Bracket (2) » Install

31. { If equipped } Front Wheel Speed Sensor Bracket Bolt (1) » Install and tighten — Fastener Specifications

32. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Install

33. Have an assistant apply the brakes.

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

34. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications
35. Install the front tire and wheel assembly. Tire and Wheel Removal and Installation
36. Remove the support and lower the vehicle.
37. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection