Wheel Stud Replacement (4WD without Z56)

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

Wheel Stud Replacement (4WD without 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

Wheel Stud Replacement (4WD without 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.

Wheel Stud Replacement (4WD without Z56) — figure 3

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

Wheel Stud Replacement (4WD without Z56) — figure 4

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

Wheel Stud Replacement (4WD without Z56) — figure 5

11. { If equipped } Front Disc Brake Pad Wear Sensor Retainer (2) » Remove
12. { If equipped } Position the front disc brake pad wear sensor wiring harness (1) out of the way.

Wheel Stud Replacement (4WD without 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)

Wheel Stud Replacement (4WD without Z56) — figure 7

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

Wheel Stud Replacement (4WD without Z56) — figure 8

17. Front Wheel Speed Sensor Bolt (2) » Remove
18. Front Wheel Speed Sensor (1) » Remove

Wheel Stud Replacement (4WD without Z56) — figure 9

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

Wheel Stud Replacement (4WD without Z56) — figure 10

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.

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

Wheel Stud Replacement (4WD without Z56) — figure 11

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

Wheel Stud Replacement (4WD without Z56) — figure 12

23. Front Wheel Hub (1) » Remove
24. Front Brake Shield (2) » Remove
25. Front Wheel Hub Seal (3) » Remove and DISCARD [2x]

Wheel Stud Replacement (4WD without Z56) — figure 13

26. Using the CH-43631 Ball Joint Separator (1) release the wheel stud (2) from the front wheel hub.

Wheel Stud Replacement (4WD without Z56) — figure 14

27. Front Wheel Stud (1) » Remove and DISCARD Installation Procedure

28. Front Wheel Stud (1) » Install NEW

Wheel Stud Replacement (4WD without Z56) — figure 15

2. Install a suitable quantity of washers (2) and an OLD wheel nut (1) to the front wheel stud (3).
3. Tighten the wheel nut (1) until the front wheel stud (3) is fully seated into the front wheel hub.
4. Remove the OLD wheel nut (1) and washers (2) from the front wheel stud (3).
5. Clean any debris and corrosion from the steering knuckle bearing pilot bore.
6. 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.

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

8. Front Brake Shield (2) » Install

9. Front Wheel Hub (1) » Install

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

Caution

Refer to Fastener Caution.

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

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

13. Front Wheel Speed Sensor (1) » Install

14. Front Wheel Speed Sensor Bolt (2) » 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.

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

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

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

18. Front Brake Rotor (2) » Install

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

20. 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: 20.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 20.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 20.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 20.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

21. Front Brake Caliper (1) » Install

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

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

24. { If equipped } Position the front disc brake pad wear sensor wiring harness (1) into place.

25. { If equipped } Front Disc Brake Pad Wear Sensor Retainer (2) » Install

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

27. 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.

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