Rear Knuckles - Tracker Off-Road 800SX Service Manual

2. Slide the knuckle onto the drive axle and into posi-
tion on the A-arms; then secure the knuckle to the
A-arms with cap screws and new lock nuts. Tighten
to 45 ft-lb (61.2 N-m).
3. Tighten the hardware securing the A-arms to the
frame mounts (from step 1) to 45 ft-lb (61.2 N-m).
4. Secure the lower shock mount to the A-arms with a
cap screw and new lock nut. Tighten to 45 ft-lb
(61.2 N-m).
5. Install the hub; then the brake caliper.
6. Install the wheels and using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre-
ments to a final torque of 100 ft-lb (136 N-m).
7. Remove the vehicle from the support stand.

Rear Knuckles

CHECK FOR DAMAGED OR WORN
BEARING, COLLAR AND BUSHINGS
1. Secure the vehicle on a support stand to elevate the
wheel.
2. Turn wheel right and left to check for free-play.
3. If any free-play is present, replace the bearing, bush-
ings and collar as applicable.
REMOVING AND DISASSEMBLING
1. With the vehicle in Park, secure the vehicle on a
support stand to elevate the wheel.
! WARNING
Make sure the vehicle is solidly supported on the
support stand to avoid injury.
2. Remove the wheel; then remove the brake caliper;
then remove the hub as described in the Hub/Brake
Disc section.
3. Remove the knuckle cap screws (A) and lock nuts
(B); then remove the knuckle. Discard lock nuts (B).
Inspect cap screws and replace if damaged.
4. If bearing (C) needs to be replaced: Remove the snap
ring (D) securing the bearing in the knuckle; then
press the bearing out of the knuckle. Discard bearing.
5. If bushings (E) need to be replaced: Remove dust
seals (F), then push collar (G) out of upper knuckle
bushings. Press the upper and lower bushings out of
knuckle. Discard bushings and collar.
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CLEANING AND INSPECTING
1. Clean all knuckle components.
2. Inspect the knuckle for cracks and breaks.
3. If replacing bushings and bearings, inspect knuckle
for galling of the bearing and bushing surface.
ASSEMBLING AND INSTALLING
1. If a bearing needs to be replaced: Using a suitable
press and driver, press a new bearing into the
knuckle until firmly seated; then install the snap ring
with the sharp edge away from the bearing.
2. If a bushing needs to be replaced: Using a suitable
press and driver, press four new bushings into
knuckle until contact is made with bushing flange.
Insert new collar and replace dust seal on the upper
knuckle bushings.
3. Slide the knuckle onto the drive axle and into posi-
tion on the A-arms; then secure the knuckle to the
A-arms with cap screws and new lock nuts. Tighten
to 45 ft-lb (61.2 N-m).
4. Grease knuckles; clean dirt or debris from the Zerk
before adding grease. Add grease to the Zerk until
any trapped air or moisture is pushed out.
5. Install the hub; then install the brake caliper as
described in the Hub/Brake Disc section.
6. Install the wheels and using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre-
ments to a final torque of 100 ft-lb (136 N-m).
7. Remove the vehicle from the support stand.