Dodge ZB 2005 Service Manual page 52

ZB
UPPER BALL JOINT (Continued)
Fig. 39 Upper Ball Joint
1 - TAPERED STUD
2 - GREASE FITTING
3 - THREADS FOR INSTALLING BALL JOINT IN CONTROL ARM
4 - BALL JOINT
DIAGNOSIS AND TESTING - UPPER BALL
JOINT (FRONT)
Ball joint replacement is necessary if more than
0.51 mm (0.02 in.) axial end play of ball joint stud
exists. Refer to following procedure to inspect ball
joint for wear.
CAUTION: When raising vehicle by lower control
arm using a floor jack, care must be used so con-
trol arm does not get nicked, gouged, deformed or
damaged in any other way by floor jack.
(1) Position floor jack under outer end of front
lower control arm. Carefully raise vehicle so front
wheel and tire assembly is just lightly contacting
floor (vehicle weight relieved from tire).
(2) Have helper grasp tire at top and apply an
inward and outward force against top of tire. While
force is being applied against tire, look for any move-
ment between upper ball joint and steering knuckle.
(3) If any lateral movement is evident at upper
ball joint, replacement is necessary.
UPPER BALL JOINT SEAL
BOOT
REMOVAL
NOTE: Review all Warnings and Cautions. (Refer to
2 - SUSPENSION - WARNING).
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(2) Remove wheel and tire assembly (Refer to 22 -
TIRES/WHEELS - REMOVAL).
(3) Remove brake caliper from knuckle and hang
out of the way, then remove brake rotor. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTOR
REMOVAL)
(4) Remove bolt fastening wheel speed sensor head
to steering knuckle (Fig. 42). Remove sensor head
from knuckle.
CAUTION: The nut must be positioned at the end of
the stabilizer bar link stud to help prevent the end
of the stud from being damaged when separating it
from the lower control arm.
(5) Remove cotter pin and nut from upper ball
joint stud (Fig. 43).
CAUTION: Do not strike or apply heat to steering
knuckle in an effort to separate ball joint studs from
steering knuckle.
CAUTION: When releasing ball joint from knuckle
using Puller, Special Tool C-4150A, use care not to
pinch and damage ball joint grease seal.
(6) Install Puller, Special Tool C-4150A, over
knuckle and ball joint stud. Ball bearing in bolt of
Special Tool C-4150A must be centered in end of
upper ball joint stud.
(7) Release upper ball joint from knuckle using
Puller. Remove tools.
(8) Move knuckle away from upper ball joint.
(9) Using a suitable cleaner, clean debris away
from seal without contaminating joint.
(10) Using a screw driver or other suitable tool,
pry seal boot off ball joint (Fig. 40).
INSTALLATION
(1) Wipe off used grease around ball joint stem.
(2) Place NEW ball joint seal boot over ball joint
stem.
(3) By hand, start seal boot bottom flange over
sides of ball joint.
(4) Position Installer, Special Tool 6761, over seal
boot aligning it with bottom flange (Fig. 41). Apply
hand pressure to the rear of Installer until seal boot
flange is pressed squarely against control arm.
Remove tool.
(5) Install upper ball joint stud into steering
knuckle. Install ball joint castle nut (Fig. 43).
Tighten castle nut to 102 N·m (75 ft. lbs.) torque.
Once nut is tightened to specified torque, it
may be necessary to continue tightening nut a
small amount to allow for cotter pin installa-
FRONT SUSPENSION 2 - 23
-