Knuckle - AWD: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Locating Halfshaft at Hub/Bearing Assembly

Courtesy of DAIMLERCHRYSLER CORP.

If hub and bearing and dust shield needs to be installed on knuckle, perform following:
- Slide shield onto rear of hub and bearing.
- Slide hub and bearing into knuckle, lining up mounting holes in hub and bearing with those in shield and knuckle
- Install four bolts (3) fastening hub and bearing in place. Tighten mounting bolts to 68 N.m (50 ft. lbs.) torque.
Fig 2: Halfshaft Isolation Washer
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NOTE: Before installing hub and bearing on end of axle half shaft, ensure isolation washer is present on end of half shaft. Inspect washer making sure it is not worn or damaged. Washer can be installed in either direction on shaft.

Fig 3: Ball Joint & Axle Attachment At Knuckle
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Place knuckle (3) over lower ball joint stud and guide hub and bearing (2) onto axle half shaft (1).
Start NEW nut (4) on lower ball joint stud. Do not tighten at this time.

Fig 4: View Of Upper Ball Joint, Spindle & Strut Mounting
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CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.
Place upper ball joint stud (1) through hole in top of knuckle and install nut (4). Tighten nut by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 47 N.m + 90° turn (35 ft. lbs. + 90° turn) torque.

Fig 5: Ball Joint & Axle Attachment At Knuckle
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.
Tighten lower ball joint nut (4) by holding ball joint stud with a hex wrench while turning nut with a wrench. Tighten nut using crow foot wrench on torque wrench to 68 N.m + 90° turn (50 ft. lbs. + 90° turn) torque.

Fig 6: Tie Rod Attachment at Knuckle
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CAUTION: It is important to tighten nut as described in following step to avoid damaging ball stud joint.
Place outer tie rod stud through hole in knuckle (3) and install nut (1). Tighten nut by holding stud with a wrench while turning nut with another wrench. Tighten nut using crow foot wrench on torque wrench to 85 N.m (63 ft. lbs.) torque.
Install brake rotor, then disc brake caliper and adapter assembly. (Refer to BRAKES/HYDRAULIC/MECHANICAL/ROTOR - INSTALLATION)

Fig 7: Locating Axle Shaft Hub Nut
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Install hub nut (1) on end of axle half shaft (2). While a helper applies brakes to keep hub from turning, tighten hub nut to 213 N.m (157 ft. lbs.) torque.

Fig 8: Wheel Speed Sensor At Front Knuckle - AWD
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Install wheel speed sensor (2) head into knuckle (4) and install mounting screw (1). Tighten screw to 11 N.m (95 in. lbs.) torque.
Attach wheel speed sensor cable routing clip (3) at knuckle (4).

Fig 9: Tire And Wheel Mounting
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Install tire and wheel assembly (1) (Refer to TIRES/WHEELS - INSTALLATION) . Tighten wheel mounting nuts (3) to 150 N.m (110 ft. lbs.) torque.
Lower vehicle.

Fig 10: Reservoir Fluid Level Markings
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Pump brake pedal several times to ensure vehicle has a firm brake pedal before moving vehicle.
Check and adjust brake fluid level in reservoir (1) as necessary.
Perform wheel alignment. (Refer to SUSPENSION/WHEEL ALIGNMENT - STANDARD PROCEDURE)