Ford Explorer: Front Suspension - RWD / Removal and Installation - Wheel Knuckle

Special Tool(s) / General Equipment

204-592 Separator, Lower Arm Ball Joint TKIT-2006C-FFMFLM TKIT-2006C-LM TKIT-2006C-ROW

Removal

NOTICE: Suspension fasteners are critical parts that affect performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

1. Remove the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. 1. Remove the bolt and position aside the wheel speed sensor harness.
      
   2. Remove the brake hose bracket bolt and position aside the brake hose.
      

1. NOTICE: Do not use power tools to remove or install the lower arm outboard nut. Damage to the ball joint or ball joint seal may occur.

   NOTE: Use the TORX PLUS® holding feature to prevent the ball stud from turning while removing or installing the lower arm outboard nut. Torx® and TORX PLUS® is a reg. tm of Acument Intellectual Properties, LLC.

   Remove and discard the front lower arm outboard nut.
   

1. NOTICE: Do not use a hammer, prying device, or separator fork to separate the ball joint from the wheel knuckle. Damage to the ball joint or ball joint seal may occur.

   NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position. Damage to the ball joint or ball joint seal may occur.

   Separate the front lower arm from the wheel Knuckle.
   Use Special Service Tool: 204-592  Separator, Lower Arm Ball Joint.

1. NOTE: If equipped.

   1. Disconnect the ride height sensor electrical connector.
      
   2. Remove the ride height sensor arm anchor plate bolt.
      

1. NOTICE: Do not use power tools to remove or install the lower arm outboard nut. Damage to the ball joint or ball joint seal may occur.

   NOTE: Use the TORX PLUS® holding feature to prevent the ball stud from turning while removing or installing the lower arm outboard nut. Torx® and TORX PLUS® is a reg. tm of Acument Intellectual Properties, LLC.

   Remove and discard the rear lower arm outboard nut.
   

1. NOTICE: Do not use a hammer, prying device, or separator fork to separate the lower arm from the ball joint. Damage to the ball joint or ball joint seal may occur.

   NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position. Damage to the ball joint or ball joint seal may occur.

   Separate the rear lower arm from the wheel Knuckle.
   Use Special Service Tool: 204-592  Separator, Lower Arm Ball Joint.

1. Remove the wheel bearing and wheel hub.
   Refer to: Front Wheel Bearing and Wheel Hub (204-01A Front Suspension - RWD, Removal and Installation).
   

1. NOTICE: Do not use a hammer to separate the tie rod end from the wheel knuckle or damage to the wheel knuckle may result.

   NOTICE: Use care when installing the tie rod separator or damage to the tie rod end boot may occur.

   NOTE: Use the hex-holding feature to prevent turning of the stud while removing the tie rod end nut.

   1. Remove and discard the tie rod end nut.
      
   2. Separate the tie rod end from the wheel knuckle.
      

1. If necessary, Remove the brake disc shield retainers and the brake disc shield.
   

1. 1. Remove and discard the lower strut-to-wheel knuckle bolts and nuts.
      
   2. Remove the wheel knuckle.
      

Installation

1. 1. Position the wheel knuckle to the lower strut assembly.
      
   2. Install the new lower strut-to-wheel knuckle bolts and nuts.
      Torque: 166 lb.ft (225 Nm)

1. If removed, Install the brake disc shield and the brake disc shield retainers.
   Torque: 80 lb.in (9 Nm)

1. NOTICE: Use care when installing the tie rod separator or damage to the tie rod end boot may occur.

   NOTE: Use the hex-holding feature to prevent turning of the stud while removing the tie rod end nut.

   1. Attach the tie rod end to the wheel knuckle.
      
   2. Install the new tie rod end nut.
      Torque: 52 lb.ft (70 Nm)

1. Install the wheel bearing and wheel hub.
   Refer to: Front Wheel Bearing and Wheel Hub (204-01A Front Suspension - RWD, Removal and Installation).
   

1. NOTE: Make sure that the mating lower arm faces are clean and free of foreign material.

   Before installing lower arm, inspect the rear lower arm housing to make sure the cavity is clean and free of foreign material.
   

1. NOTICE: Do not use power tools to remove or install the lower arm outboard nut. Damage to the ball joint or ball joint seal may occur.

   NOTE: Use the TORX PLUS® holding feature to prevent the ball stud from turning while removing or installing the lower arm outboard nut. Torx® and TORX PLUS® is a reg. tm of Acument Intellectual Properties, LLC.

   1. Attach the rear lower arm to the wheel knuckle.
      
   2. Install the new rear lower arm outboard nut.
      Torque:
         Type-1, Police and HEV (hybrid electric vehicle), M16 for Heavy Duty:   173 lb.ft (235 Nm)
         Type-2, GAS vehicles, M14 for Standard Duty:   85 lb.ft (115 Nm)

1. NOTE: If equipped.

   1. Install the front ride height sensor arm anchor plate bolt.
      Torque: 97 lb.in (11 Nm)
   2. Connect the ride height sensor electrical connector.
      

1. NOTE: Make sure that the mating wheel knuckle faces is clean and free of foreign material.

   Before installing a new front lower arm, inspect the knuckle to make sure the cavity is clean and free of foreign material.
   

1. NOTICE: Do not use power tools to remove or install the lower arm outboard nut. Damage to the ball joint or ball joint seal may occur.

   NOTE: Use the TORX PLUS® holding feature to prevent the ball stud from turning while removing or installing the lower arm outboard nut. Torx® and TORX PLUS® is a reg. tm of Acument Intellectual Properties, LLC.

   1. Attach the front lower arm to the wheel knuckle.
      
   2. Install the new front lower arm outboard nut.
      Torque: 76 lb.ft (103 Nm)

1. 1. Position the brake hose and install the brake hose bracket bolt.
      Torque: 133 lb.in (15 Nm)
   2. Position the wheel speed sensor harness and install the bolt.
      Torque: 106 lb.in (12 Nm)

1. Install the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Check and if necessary adjust front toe.
   Refer to: Front Toe Adjustment (204-00 Suspension System - General Information, General Procedures).
   

1. NOTE: If equipped.

   Calibrate the suspension height sensor. Connect the scan tool and carry out the Ride Height Calibration routine. Follow the scan tool directions.