truck (99 ranger 4x4 PVH) is apart and i have a new main knuckle vacuum seal that needs to go on. but how do you get the old one off and the new one on???? is removale of the knuckle needed in order to access it from the back??? or does it pop out the front?? i REALLY dont want to spemd another 200+ to have my 4x4 going. anyone HELP!!

 

This is out of my '98 Manual:

WHEEL KNUCKLE

REMOVAL

1. Remove the wheel hub.

2. Remove the torsion bar.

CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft.

3. Suspend the front axle shaft with wire.

4. Remove the tie-rod end castellated nut.
- Remove the cotter pin.
- Remove the castellated nut.

5. Using the Pitman Arm Puller, separate the tie-rod end from the front wheel knuckle.

6. Remove the lower ball joint castellated nut.
- Remove the cotter pin.
- Remove the castellated nut.

7. Using the Pitman Arm Puller, separate the front wheel knuckle from the front suspension lower arm.

8. Remove the pinch bolt, nut and the front wheel knuckle.

NOTE: The knuckle main seal should only be removed from the knuckle if it is damaged or failed the leak test. The main seal cannot be reused once it has been removed from the knuckle.

9. Using a drift and a hammer, remove the main seal from the knuckle.

10. Thoroughly clean the knuckle's main seal bore.
- Clean the main seal bore.
- Using the shop air supply, thoroughly flush the vacuum hose and the knuckle vacuum chambers.

11. Inspect the knuckle main seal bore for any damage, nicks, burrs or pitting.

12. Inspect the steel vacuum line for damage or corrosion. If the vacuum line is damaged or corroded, a new knuckle must be installed.


INSTALLATION

1. Apply a thin coat of Ford High Temperature Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1C198-A to the bore of the knuckle.

2. Install the main seal.
- Position the main seal into the special tools, then install the special tool onto the knuckle.
- Turn the bolt until the special tool seats against the knuckle.

3. Remove the special tool.

CAUTION: Apply at least 3 grams of grease to the sealing surface of the main seal. Failure to do so can cause premature failure of the main seal, resulting in damage to the axle shaft or wheel knuckle, or loss of four-wheel drive.

4. Apply a generous coat (3 grams or more) of Ford High Temperature Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A to the sealing faces of the main seal.

5. Install the pinch bolt and nut.
- Position the upper arm into the front wheel knuckle.
- Install the pinch bolt and nut.

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 Ford High Temperature Wheel Bearing Grease E8TZ-19590-A meeting Ford specification ESA-M1C198-A 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.
- Position the lower ball joint into the front wheel knuckle.
- Install the castellated nut.
- Install a new cotter pin.

9. Install the tie-rod end castellated nut.
- Position the tie-rod end.
- Install the castellated nut.
- Install a new cotter pin.

10. Install the torsion bar.

11. Install the wheel hub.

12. Lower the vehicle.

13. Perform the wheel-end vacuum leak test.

14. Check the ride height.

15. Check the alignment.