Wheel Knuckle: Removal

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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Remove the front brake disc. For additional information, refer to BRAKE DISC .
Remove the wheel hub and bearing. For additional information, refer to WHEEL HUB .
If equipped, disconnect the pulse vacuum hub (PVH) hose.
Using a drift, drive the axle shaft main seal out of the wheel knuckle.

Fig 1: Removing Axle Shaft Main Seal
Courtesy of FORD MOTOR CO.
Remove the axle shaft and main seal.

Fig 2: Removing Axle Shaft And Main Seal
Courtesy of FORD MOTOR CO.
Remove the tie-rod end castellated nut.
1. Remove the cotter pin.
2. Remove the castellated nut.
  
  Fig 3: Removing Castellated Nut
  Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Fig 4: Disconnecting Tie-Rod End Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, disconnect the tie-rod end from the wheel knuckle.
Remove the upper ball joint castellated nut and the insert.
1. Remove the cotter pin.
2. Remove the nut.
3. Remove the insert.
  
  Fig 5: Removing Upper Ball Joint Castellated Nut
  Courtesy of FORD MOTOR CO.
Remove the wheel knuckle.
1. Remove the lower ball joint nut.
2. Remove the knuckle.
  
  Fig 6: Removing Lower Ball Joint Nut
  Courtesy of FORD MOTOR CO.
Clean and inspect the wheel knuckle ball joint bores.