Safari Van 2WD V6-4.3L VIN X (2003)
9.
Using tool J 23742, Ball Joint Separator, separate the lower ball joint from the steering knuckle.
10.
Remove tool J 23742.
11.
Carefully lower the lower control arm until the ball joint has cleared the knuckle and the support can be removed.
12.
With the knuckle still attached to the upper ball joint, carefully swing the lower portion of the knuckle forward. Then for the right side knuckle,
rotate the knuckle as if making a slight left turn. For the left side knuckle, rotate the knuckle as if making a right turn.
13.
Using a shop towel, clean the top and bottom side of the knuckle where the lower ball joint is attached.
Notice
The inspection, and grinding if necessary, described in the next steps must be performed before using the cutter tool. Failure to perform the
inspection, and grinding if necessary, will result in damage to the blades on the cutter tool.
Important
Due to variation in the casting molds used during manufacturing, some knuckles were made with additional or extra casting material (1) along
the horizontal surface directly outboard of the hole (3) where the lower ball joint stud attaches. This additional casting material will vary in
size and thickness and must be removed BEFORE using the cutter tool. In the above illustration, the knuckle on the right is an example of a
knuckle manufactured WITHOUT the extra casing material. The horizontal surface (2) is smooth from side to side. The one on the left shows a
knuckle WITH the extra material (1) that must be removed. The illustration in the small box in the upper left corner of the illustration shows
how much of the extra casting material (4) must be removed in the next steps. The illustration in the small box in the upper right corner shows
how the knuckle should look after the extra material (5) has been remove.
14.
Inspect for the presence of the extra casting material at the two locations (1) shown in the above illustration.
^
If no extra casting material is found, proceed to Step 16. Do not perform Step 15.
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If extra casting material is found at either location on a knuckle, proceed to Step 15 and remove the casting material.
Important
It is only necessary to remove some of the extra casting material in the next step. The section to be removed should be approximately 10 mm
(3/8 in) long and the width of the extra material. Remove only as much material as instructed and shown in the above illustration. The shaded
area in the illustration above represents the amount of material to remove at each location.
