Contents: Disassembly ⇩ Assembly ⇩
| Pos. | Spare part number | Name |
| 1. | - | Steering knuckle |
| 2. | - | Upper kingpin and brake hose bracket |
| 3. | - | Upper and lower kingpin bearings |
| 4. | - | Adjusting shim |
| 5. | - | Locking bar and washer |
| 6. | - | Oil seal |
| 7. | - | Pad |
| 8. | - | Kingpin bearing housing |
| 9. | - | Pad |
| 10. | - | Lower kingpin |
| 11. | - | Mudguard bracket |
| 12. | - | Inner oil seal of steering knuckle |
Disassembly
1. Remove the front hub assembly.
For more information, see: Wheel Bearing and Wheel Hub - Vehicles Built Up To: 01/1999 (204-01, Removal and installation) / Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
2.
NOTE: On later vehicles the knuckle is filled with grease for life. There are no check or drain plugs.
Drain the steering knuckle and replace the plug.
3. Remove the 6 bolts securing the splined axle shaft to the steering knuckle.
4. Remove the mudguard.
5. Remove the splined axle shaft and gasket.
6. Remove the axle shaft and constant velocity joint from the drive axle housing.
7. Clamp the axle shaft securely in a vice with soft jaws.
8. Using a soft faced hammer, remove the constant velocity joint from the axle shaft.
9. Remove the retaining ring and sleeve from the axle shaft.
10. Mark the position of the constant velocity joint, inner and outer races and cage to facilitate assembly.
11. Rotate the separator and inner ring to remove the balls.
12. Inspect all components, in particular the inner and outer rings, separator balls and bearing running surfaces for damage and excessive wear.
13. The maximum allowable axial clearance of the assembled joint is 0.64 mm. Replace if worn or damaged. Lubricate with the recommended oil during assembly.
Assembly
1. Install the bushing and new retaining ring.
2. Place the constant velocity joint onto the axle shaft splines and use a soft faced hammer to fully seat the joint.
3. Drill and chisel the thrust ring, being careful not to damage the splined axle shaft.
4. Remove the bearing and oil seal using the special tool LRT-37-004 and the impact puller LRT-99-004. Make sure the tool tab is positioned behind the bearing to remove it.
5. Repeat according to the instructions for removing the oil seal.
6. Lubricate the seal and lip with EP90 oil and, using the special tool LRT-54-004, install the new oil seal with the cavity side first.
7. Using special tool LRT-54-005, install the bearing so that the spare part number is visible after installation. The bearing should be flush with the end surface of the splined axle shaft.
8. Press a new thrust ring onto the splined axle shaft.
9.
NOTE: Removal of the oil seal and retaining plate becomes possible after removal of the kingpin bearing housing.
Remove the oil seal retaining plate and gasket mounting bolts. Remove the assembly from the steering knuckle.
10. Remove the two bolts securing the lower kingpin to the steering knuckle.
11. Remove the brake disc shield bracket.
12. Tap the tab to remove the lower kingpin and gasket.
13. Remove the two bolts securing the brake hose bracket and the upper kingpin.
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14. Remove the bracket, upper kingpin and adjusting shims.
15. Remove the kingpin when removing the lower and upper bearings.
16.
NOTE: Use the upper bearing hole to gain access to the lower bearing race.
Remove the lower bearing race from the kingpin bearing housing.
17. Remove the 7 bolts securing the kingpin bearing housing to the axle housing.
18. Remove the inner oil seal from the rear of the steering knuckle.
19.
NOTE: Use the lower bearing hole to gain access to the upper bearing race.
Remove the upper bearing race from the kingpin bearing housing.
20. Replace the steering knuckle if it is worn, corroded or damaged.
21.
CAUTION: Do not tilt the bearing races when installing. Otherwise, damage may occur.
Install the upper and lower bearing rings into the kingpin bearing housing.
22. Install the inner knuckle oil seal into the rear of the knuckle, with the sealing lips facing outward. Lubricate the sealing lips.
23. Apply sealant, part number STC 50552, to the bolts securing the kingpin bearing housing to the drive axle housing.
24. Apply sealant to both sides of the gasket. Position the kingpin bearing housing against the mating surface of the axle.
25. Install the retaining plate, gasket and oil seal onto the axle flange in preparation for assembly.
26. Secure the kingpin bearing housing to the axle flange with 7 bolts. Tighten to 73 Nm.
27. Lubricate and install the upper and lower kingpin tapered roller bearings.
28. Position the steering knuckle over the kingpin bearing housing.
29. Apply sealant to both sides of the gasket and install the washer onto the lower kingpin.
30. Without securing, install the brake shield bracket plus lower kingpin with the protrusion facing outward onto the steering knuckle.
31. Without securing, install the upper kingpin plus any shims and brake hose bracket onto the steering knuckle.
32. Apply sealant, part number STC 50552, to the threads of the lower kingpin bolts. Tighten the bolts to 25 Nm, bend back the locking tabs.
33. Apply sealant, part number STC 50552, to the threads of the upper kingpin mounting bolts, install the bolts and tighten to 65 Nm.
34.
NOTE: The steering knuckle oil seal and axle should not be installed.
Attach a dynamometer to the ball joint hole of the tie rod and pull the dynamometer to determine the force required to turn the steering knuckle. The resistance after overcoming the initial inertia should be in the range of 1.16 to 1.46 kg. Adjust by removing the adjusting shims or adding them to the steering knuckle.
35. Once the correct adjustment has been made, remove the upper kingpin mounting bolts. Apply sealant, part number STC 50552, to the bolt threads. Install the bolts and tighten to 65 Nm; bend back the locking tabs.
36. Apply the recommended lubricant between the lips of the steering knuckle oil seal.
37. Install the oil seal, gasket and locking plate. Secure with 7 bolts using spring washers. Tighten to 10 Nm.
38. Install the transverse and longitudinal steering rods and secure with new cotter pins. Tighten the fastening element with a force of 40 Nm.
39. Install the brake disc shield.
40. Without tightening, screw in the kingpin stop bolt and nut.
41. Apply the recommended lubricant between the lips of the steering knuckle oil seal.
42. Secure the oil seal using the retaining bar and clamp bolts. Tighten to 10 Nm.
43. Install the transverse and longitudinal steering rods and secure with new cotter pins.
44. Without tightening, screw in the kingpin stop bolt for later adjustment.
45. Install the brake disc shield.
46.
CAUTION: Be careful not to damage the axle shaft oil seals.
Install the axle shaft and after engaging with the differential splines, insert the assembly completely.
47. Install a new gasket to the mating surface between the steering knuckle and the splined axle shaft. Apply sealant, part number STC 50552, to the splined axle shaft bolt threads.
48.
CAUTION: Before securing the wheel axle, make sure the constant velocity joint bearing journal is positioned against the thrust washer on the axle shaft spline.
Install the splined axle shaft so that the chamfer is at the 12 o'clock position.
49. Install the mudguard and use 6 bolts to connect the splined axle shaft to the steering knuckle. Tighten the bolts evenly to 65 Nm.
50. Secure the connecting brake hoses to the appropriate bracket.
51. Install the front hub assembly.
For more information, see: Wheel Bearing and Wheel Hub - Vehicles Built Up To: 01/1999 (204-01, Removal and installation) / Front Wheel Bearing and Wheel Hub (204-01 Front Suspension, Removal and Installation).
52. Check for the presence of the oil drain plug in the steering knuckle.
53. Remove the inspection and filler plugs from the steering knuckle.
54.
NOTE: On later vehicles, fill the steering knuckle with 0.33L of Molytex EP 00 grease.
Check the level and add new oil until the oil starts to flow out of the inspection hole. Drain off any excess oil and wipe the surrounding area dry.
For more information, please refer to the chapter: Specifications (205-03 Front Drive Axle/Differential, Specifications).
55. Screw the inspection and filler plugs into the steering knuckle.
56. Adjust the kingpin stop bolts.
For more information, please refer to the chapter: Steering Lock Stop Adjustment (211-00 Steering System -General Information, General Procedures).
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