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Home >> Ford >> 2004 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 587 (Front Suspension - Four Wheel Drive (4WD) -- F250-F550 Super Duty) >> Removal And Installation >> Wheel Knuckle >> Installation

Wheel Knuckle: Installation

WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the wheel knuckle onto the axle housing.
  2. Install the nut onto the lower ball joint. Do not tighten the nut at this time.
    Fig 1: Installing Nut Onto Lower Ball Joint
    G03904176Courtesy of FORD MOTOR CO.
  3. Install the insert and the castellated nut onto the upper ball joint. Do not tighten the nut at this time.
    Fig 2: Inserting Castellated Nut Onto Upper Ball Joint
    G03904177Courtesy of FORD MOTOR CO.
  4. Tighten the lower ball joint retaining nut. Pre-tighten the nut to 64 Nm (47 lb-ft).
    Fig 3: Tightening Lower Ball Joint Retaining Nut
    G03904178Courtesy of FORD MOTOR CO.
    5. NOTE: Do not loosen the castellated nut to install the cotter pin.
  5. Install the cotter pin into the upper ball joint.
    1. Tighten the upper ball joint castellated nut.
    2. Install the cotter pin. If necessary, tighten the castellated nut until the cotter pin can be installed.
      Fig 4: Tightening Upper Ball Joint Castellated Nut
      G03904179Courtesy of FORD MOTOR CO.
  6. Tighten the lower ball joint nut to 204 Nm (150 lb-ft).
  7. Install the tie-rod end onto the wheel knuckle.
    1. Position the tie-rod end into the wheel knuckle.
    2. Install and tighten the castellated nut.
    3. Install the cotter pin.
      Fig 5: Tightening Castellated Nut
      G03904180Courtesy of FORD MOTOR CO.
  8. Install the new main seal onto the axle shaft.
    1. Position the main seal onto the axle shaft.
    2. Using the special tools and a hammer, seat the main seal onto the axle shaft.
      Fig 6: Installing Seat Main Seal Onto Axle Shaft
      G03904181Courtesy of FORD MOTOR CO.
  9. Position the axle shaft into the axle housing.
    10. CAUTION: The knuckle bore must be clean enough to allow the special tool to seat completely by hand. Do not press or draw the wheel knuckle seal and axle shaft into place.
    CAUTION: Do not apply any lubricant to the surface of the wheel knuckle bore.
  10. Clean and inspect the wheel knuckle bore. If the wheel knuckle is cracked, a new one must be installed.
  11. Position the special tool onto the axle shaft and install the snap ring.
    Fig 7: Positioning Special Tool Onto Axle Shaft
    G03904182Courtesy of FORD MOTOR CO.
  12. Using the special tools, install the wheel knuckle seal and axle shaft.
    Fig 8: Installing Wheel Knuckle Seal And Axle Shaft
    G03904183Courtesy of FORD MOTOR CO.
  13. Install the wheel hub and bearing. For additional information, refer to WHEEL HUB .
  14. Install the front brake disc. For additional information, refer to BRAKE DISC .
  15. If equipped, connect the pulse vacuum hub (PVH) hose.
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