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Knuckle - AWD: Removal

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.
  1. Raise and support vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
    Fig 1: Tire And Wheel Mounting
    GC0012971Courtesy of DAIMLERCHRYSLER CORP.
  2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).
    Fig 2: Locating Axle Shaft Hub Nut
    GC0014039Courtesy of DAIMLERCHRYSLER CORP.
  3. While a helper applies brakes to keep hub from rotating, remove hub nut (1) from axle half shaft (2).
    Fig 3: Wheel Speed Sensor At Front Knuckle - AWD
    GC0014045Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove clip (3) fastening wheel speed sensor (2) to knuckle (4).
  5. Remove screw (1) fastening wheel speed sensor (2) to knuckle (4). Pull sensor head (4) out of knuckle.
  6. Access and remove front brake rotor. (Refer to BRAKES/HYDRAULIC/MECHANICAL/ROTOR - REMOVAL)
    Fig 4: Tie Rod Attachment at Knuckle
    GC0013294Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove nut (1) from outer tie rod end (2) stud.
    Fig 5: Using Puller on Outer Tie Rod
    GC0014046Courtesy of DAIMLERCHRYSLER CORP.
  8. Using Puller (2), Special Tool 9360, separate tie rod stud (1) from knuckle.
    Fig 6: Ball Joint & Axle Attachment At Knuckle
    GC0014043Courtesy of DAIMLERCHRYSLER CORP.
  9. Loosen nut (4) attaching lower control arm ball joint stud to knuckle (3). Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step. 
    Fig 7: Using Puller on Lower Ball Joint - AWD
    GC0014044Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.
  10. Using Puller (2), Special Tool 9360, separate ball joint stud from knuckle.
  11. Remove tool.
  12. Remove nut (1) from end of ball joint stud.
    Fig 8: View Of Upper Ball Joint, Spindle & Strut Mounting
    GC0014047Courtesy of DAIMLERCHRYSLER CORP.
  13. Loosen nut (4) attaching upper ball joint stud (1) to knuckle. Back nut off until nut is even with end of stud. Keeping nut on at this location will help keep end of stud from distorting while using Puller in next step. 
    Fig 9: Using Puller on Upper Ball Joint
    GC0014048Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: In following step, use care not to damage ball joint seal boot while sliding Puller, Special Tool 9360, into place past seal boot.
  14. Using Puller (2), Special Tool 9360, separate upper ball joint stud (1) from knuckle.
  15. Remove tool.
  16. Remove nut (1) from end of upper ball joint stud.
    Fig 10: Ball Joint & Axle Attachment At Knuckle
    GC0014043Courtesy of DAIMLERCHRYSLER CORP.
  17. Slide knuckle (3) off half shaft (1) and remove from vehicle.
    Fig 11: Locating Halfshaft at Hub/Bearing Assembly
    GC0014038Courtesy of DAIMLERCHRYSLER CORP.
  18. If hub and bearing and dust shield need to be removed:
    • Remove four bolts (3) fastening hub and bearing (2) to knuckle.
    • Slide hub and bearing out of knuckle along with shield.
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