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Home › Mazda › 2002 › B4000 Base, Automatic › Repair and Diagnosis › Suspension › Front Suspension System › Knuckle › Removal/Installation › Knuckle Installation

Knuckle Installation

  1. Apply a thin coat of grease to the bore of the knuckle.
  2. Install the main seal.
    1. Position the main seal into the special tools, then install the special tool onto the knuckle.
    2. Turn the bolt until the special tool seats against the knuckle.
      Fig 1: Seating Tool Against Knuckle
      G00379114Courtesy of MAZDA MOTORS CORP.
  3. Remove the special tool.
    CAUTION: Failure to lubricate the main seal can cause premature wear of the seal, resulting in damage to the axle shaft and/or wheel knuckle.
  4. Apply a generous coat (3 grams or more) to the sealing faces of the main seal.
    Fig 2: Applying Grease To Seal
    G00379115Courtesy of MAZDA MOTORS CORP.
  5. Install the pinch bolt and nut.
    1. Position the upper arm into the front wheel knuckle.
    2. Install the pinch bolt and nut. See Figure .
  6. Position the axle halfshaft into the wheel knuckle bore.
    CAUTION: Make sure that no dirt or foreign material is present on the axle main seal before or after applying grease to seal. Failure to do so will cause the axle main seal to fail resulting in the loss of vacuum sealing.
  7. Apply a coating of high temperature wheel bearing grease or equivalent to the axle main seal prior to seating the axle shaft against the main seal.
    CAUTION: Install the cotter pin into the lower ball joint from outboard to inboard. Failure to do so will cause damage to the wheel and tire assembly.
  8. Connect the front suspension lower arm to the front wheel knuckle.
    1. Position the lower ball joint into the front wheel knuckle.
    2. Install the castellated nut.
    3. Install a new cotter pin.
      Fig 3: Installing Lower Front Suspension Bar
      G00379116Courtesy of MAZDA MOTORS CORP.
  9. Install the tie rod end castellated nut.
    1. Position the tie rod end.
    2. Install the castellated nut.
    3. Install a new cotter pin.
      Fig 4: Installing Tie-End Rod
      G00379117Courtesy of MAZDA MOTORS CORP.
  10. Install the torsion bar. See TORSION BAR  .
  11. Install the wheel hub. See WHEEL HUB (4X4) .
  12. Lower the vehicle.
  13. Check the ride height. See WHEEL ALIGNMENT SPECIFICATIONS .
  14. Check the alignment. See WHEEL ALIGNMENT SPECIFICATIONS .
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