Page 1137 of 2189

)
20, Remove the cotter pin from the lower arm ball joint
castle nut. and remove the nut.
COTTER.PINReplace.On reassembly,bend the cotter Pan
lr
CASTLE NUT12 x 1.25 mm49 - 59 N.m (5.0 - 6.0 kgl m,36-,13 lbf'ft|
BALL JOINT REMOVER, 28 mm
07MAC - SL00200
21. lnstall a 12 mm hex nut onto the ball joint. Be sure
that the hex nut is flush with the ball joint pin end'
or the threaded section of the ball joint pin might be
damaged by the ball joint remover.
22. Use the special tool as shown on page l8-12 to sep-
arate the ball ioint and lower arm.
NOTE; lf necessary, apply penetrating type lubri-
cant to loosen the ball joint.
lJ
18-13
25.
26.
Remove the cotter pin from the upper ball joint cas-
tle nut, and remove the nut.
12 mm HEX NUT 07MAC - SL00200
lnstall the 12 mm hex nut onto the ball joint
Be sure that the hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
mlght be damaged by the ball joint remover'
Use the special tool as shown on page l8-12 to sep-
arate the ball joint and knuckle.
NOTE: lf necessary, apply penetrating type lubri
cant to loosen the ball joint.
Putl the knuckte outward and remove the driveshaft
outboard joint from the knuckle by tapping the drive-
shaft end with a plastic hammer, then remove the
knuckle.KNUCKLE
'12 x 1.25 mm39 - 47 N.m
14.0 - 4.8 kgf m,29 - 35 tbf.ft)
Check for damage.
Page 1138 of 2189

Front Suspension
Knuckle/Hub Replacement (cont'dl
NOTE: Replace the bearing with a new one after removal.
27. Separate the hub from the knuckle using the special
tools and a hydraulic press.
CAUTION:
o Take cale not to distort the splash guard.
. Hold onto the hub to keep it from falling whon
pr$sed clear,
. To prevenl damage to the tool. mak€ sure the
threads are fully engaged belore pressing.
HUB DIS/ASSEMBLYPILOT,38 mm07JAF - SH20110
HUB DIS/ASSEMALYSHAFT.22.{ x 25.4 mm07JAF - SH20120
28. Remove the circlip and the splash guard from the
knuckle.
Press
BEARTNG tSEPARATOR -O - 1112 in.(Commercially available)
Check tor bending and damage.
18-14
29. Press the wheel bearing out ofthe knuckle using the
special tools and a Dress as shown,
DRIVER07749 - (X)l 0000
Pross
t
KNUCKLE
ATTACHMENT,62x68mm07746 - 0010500
HUB DIS/ASSEMBLY BASE07GAF - SEoo4Ol
Press the wheel bearing
using the special tools, a
press as shown.
WHEEL BEARINGReplace.
inner race from the hub
bearing separator, and a
HUB DIS,/ASSSMBLYPILOT, 38 mm07JAF - SH20110
KNUCKLE
FRONT I{U8
HUB DIS/ASSEMBLYSHAFT,22.4 x 25.4 mm07JAF - SH20120
Page 1139 of 2189

I
NOTE: Wash the knuckle and hub thoroughly in
high flash point solvent before reassembly.
31. Press a new wheel bearing into the knuckle using
the specialtools and a press as shown
NOTE: Place the wheel bearing onto the knuckle
with the pack seal (metal color) toward the inside
Be careful not to damage the sleeve of the pack
seal.
Press
HANOI.E07749 - 001
DRIVERATTACHMENT58x72mm07947 - 6340201
DOUBLE LIP SEAL
{BLACK COLOR)
KNUCKLE
SUPPORT BASE07965 - SD90100
Installthe circlip securely in the knuckle groove'
Installthe splash guard, and tighten the screws.
scREws5 N.m (0.5 kgd m, 4lbt'ft)
32.
33.
l-,
18-15
34. lnstall the hub on the knuckle using the specialtools
shown and a hydraulic press as shown.
CAUTION: Take care not to distort tho splash gusrd'
HUB/ASSEMBLYGUIDE ATTACHMENT07GAF- SEflt2d)
KNUCKLE
FRONT HUB
SUPPORT BASE
07966 - StXx)100SPLASH GUARD
tnstall the knuckle in the reverse order of removal'
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle.
. Torque all mounting hardware to the specified
torque valugs.
. Torque the castls nuts to the low€r torque specl-
fications, then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. lnstall new cotter pins into the castle nuts after
torquing.
. Avoid twistin0 the sensor wires when installing
the wheel ssnsor.
. Before installing the brake disc, clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the wheel, clean the mating sur-
face ofthe brake disc and the inside of the wheel
. Check the front wheel alignment, and adjust it if
necessary (see page 18-4).
Page 1140 of 2189

Front Suspension
L
Lower Ball Joint Replacement
Remove the knuckle (see page 18-11).
Remove the boot by prying the set ring off.
Check the boot for deterioration and damage.
replace if necessary.
Install the special tools onto the ball joint and tight-
en the casfle nut.
Position the special tools over
shown. then set the assembly in
ball joint out of the knuckle,
BALL JOINT REMOVER/INSTALLER07965 - SB00r00
CASTLE NUT
the ball joint as
a vise. Press the
lf
7.
BALL JOINT REMOVER BASE07JAF - SH20200
Place the ball joint in position by hand.
Install the special tools over the ball joint as shown,
then press the ball joint in.
BALL JOINT INSTALLEB BASE07965 - 5800200
BALL JOINT HOUSING SURFACE
18-16
8. Install the ball joint boot and set ring using the spe-
cial tool (see page 18-16).
ADJUSTING BOLTAdjust rhe depth byturning the bolt.
Install the knuckle in the reverse order of removal,
and pay particular attention to the following items:
. Be careful not to damage the ball joint boots
when installing the knuckle,
. Torque all mounting hardware to the specified
torque values.
. Torque the castle nuts to the lower torque speci-
fications. then tighten them only far enough to
align the slot with the pin hole. Do not align the
castle nut by loosening.
. Install new cotter pins into the castle nuts after
torquang.
. Avoid twisting the sensor wires when installing
the wheel sensor.
. Before installing the brake disc. clean the mating
surfaces of the front hub and the inside of the
brake disc.
. Before installing the wheel, clean the mating sur-
face of the brake disc and the inside of the wheel.. Check the front wheel alignment, and adjust it if
necessary {see page 18-4).
Page 1141 of 2189

Front Damper
!Ball Joint Boot RePlacement
1.Remove the set ring and the boot.
CAUTION: Do not contaminate the boot installa-
tion section with grease.
Pack the interior of the boot and lip with grease
EALL PIN TAPERED SECTION
EOOT INSTALLATION SECTION
Wipe off the grease.BOOT INSTALLATION SECTION
Wipe off the grease.
lJ
3. Wipe the grease off the sliding surface of the ball
pin and pack with fresh grease.
CAUTION:
. Keep grease off the boot installation section and
the tapeled section of the ball pin.
5.
. Do not allow dust, dirt, or other toreign materi-
als to enter the boot.
Install the boot into the groove of the boot installa-
tion section securely, then bleed the atr.
Install the upper and lower ball joint boot set rings
using the special tools as follows:
Lower ball joint: Adiust the special tool with the
adjusting bolt until the end of the tool aligns with
the groove on the boot. Slide the set ring over the
tool and into Position.
BALL JOINTAOJUSTING BOLTAdjust the depth by
turning the bolt.BOOT CLIPGUIDE
4.
UPPER EALLJOINT EOOT:07GAG - SD40700LOWER BALLJOINT BOOT:07974 - SA50700
CAUTION: After installing the boot, check the ball
pin tapsrod section fol grease contamination and
wipe it if necessary.lt
18-17
Removal
l. Remove the front wheels (see page 18-11).
2, Remove the damper pinch bolt trom the top of
damper fork.
DAMPER FORK
OAMPERFORKBOLT
OAMPERPINCHAOLT10 x 1.25 mm
SELF-LOCKING NUT12 x 1.25 mmReplace.
Remove the damper fork bolt and self-locking nut
from the bottom of the damper fork, then remove
damper fork.
Remove the damper by removing the two nuts
DAMPER
Page 1142 of 2189

Front Damper
Disassembly/lnspection
Disassembly'1. Compress the damper spring with the spring com-pressor according to the manufacturer,s instruc-
tions, then remove the self-lockino nut.
CAUTION: Do not compress the spring more thann€cessary to remove the nut.
10 mm SELF-LOCKING NUTReplace.
STRUT SPRINGCOMPRESSOR:(Commerci.lly availabl.lBRANICKO T/N MST.s8I}A, T/N 7200,or eouivalent
Release the pressure from thg spring compressor,
then disassemble the damper as shown in the next
column.
Inspostion
1. Reassemble all parts, except the spring.
2. Push on th€ damper assembly as shown.
Check for smooth operation through a full stroke,
both compression and extension,
NOTE: The damper should move smoothlv. lf itdoes not (no compression or no extension), the gas
is leaking, and the damper should be replaced.Check for oil leaks, abnormal noises, or binding dur-ing these tests.
18-18
DAMPER UNIT
Replace.
DAMPER MOUNTING WASHER
BASE
DAMPER MOUNTINGBUBBERCheck for deteriorationand damage.
DAMP€R SPf,INGCheck tor weakened compressionand damage.
SPBING MOUNTING RUBBERCheck for deteriorationand damage,
BUMP STOPCheck fordamage.
DUST COVERPLATE
and
BUMP STOP PLATE
OUST COVERCheck for bending and damage.
Page 1143 of 2189
\Reassembly
2.
't.
lr
Install the damper unit on a spring compressor.
Assemble the damper in reverse order of removal
except the damper mounting washer and self lock-
ing nut.
NOTE: Align the bottom of the damper spring and
spring lower seat as shown.
STRUTSPRING COMPRESSOR:
lcommercially availablelBRANICK@ T/N MST.58OA, T/N 7200,
or 6quival€nt
SPBING LOWER SEAT
Position the damper mounting base onto the
damper unit as shown.
Compress the damPer sPring.
Install the damper mounting rubber, damper mount-
ing washer, and a new 10 mm self-locking nut.
Hold the damper shaft. and tighten the 10 mm self-
locking nut.
SELF-LOCKING NUT10 x 1.25 mm29 N.m 13.0 kgf m, 22 lbf ft)
3.
4.
Replace.
DAMPERMOUNTING WASHER
(l-t
lnstallation
1. Loosely install the damper onto the frame with the
aligning tab facing inside. then loosely install the
two flange nuts.
FLANGE NUTS10 x 1 ,25 mm49 N.m (5.0 kgt'm, 36 lbf'ftl
DAMPER ASSEMBLY
{cont'd)
18-19
Page 1144 of 2189
Front Damper
Installation (cont'd)
2. Install the damper fork over the driveshaft and onto
the lower arm. Install the front damper into the
damper fork so the aligning tab is aligned with the
slot in the damper fork.
ALIGNING TAB
DAMPERPINCHEOLT10 x 1.25 mm43 N.m 14.4 kgf.m, 32 lbtftl12 x 1.25 mm64 N.m 16.5 kgl.m, 47 lbtftlReplace.
Loosely install the damper pinch bolt into the top ofthe damper fork.
Loosely install the damper fork bolt and a new self-locking nut into the bottom of the damper fork.
Raise the knuckle with a floor jack until the vehiclejust lifts off the safety stand.
@E The ftoor ilck must be sscuroty posi-
lionsd or personal iniury may r€€uh.
Tighten the damper pinch bolt.
Tighten the damper fork bolt and self-locking nut.
Tighten the flange nuts on top of the damper.
Install the brake hose mounts with the brake hose
mounting bolts.
Install the front wheel.
7.
8.
9.
10.
1a-20