Service Procedure
Service ProcedureRework Instructions
The following details the procedure to replace the sealing boots on the ball joint.
All four front suspension lower control arm ball joints are affected by the condition and require replacement of the ball joint sealing boots.
Ball Joint Seal Kit 92245647 includes sufficient parts for one vehicle. The kit includes the following parts:
Ball Joint Sealing Boot 4
Small Retainer 4
Large Retainer 4
Attaching Bolt- Front LCA 2
Attaching Bolt- Rear LCA 2
Note
The prevailing torque nuts used to attach ball joints to the steering knuckle may be re-used once, for this field action only. Requirement to consider these as single use only for normal service replacement has not changed.
Boots and retainers are not available separately. If a component of the ball joint seal kit is damaged, or otherwise unusable, it will be necessary to obtain a complete replacement kit.
Tools Required
- E7115 Angle Wrench or J 45059 Angle Wrench/Meter
- J 42188-B Ball Joint Separator
- J 46620 (Used to install large ball joint retainer)
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Remove the control arms from vehicle. Refer to Control Arm Replacement and Front Lower Control Arm Replacement in SI.
Note
It is recommended that the replacement of each boot is completed before commencing the next ball joint. The order in which replacement is carried out is not critical. Disassembly and assembly of sealing boots should be regarded as an extremely sensitive operation. Special care should be taken by technicians to avoid scratching or damaging housings, allowing contamination into the joint, damaging or puncturing boots, overstretching clamp rings, damaging tapers or threads.
3. Place the control arm on a work bench and remove the ball joint sealing boot and retainers from the control arm. If a vice is used to secure the control arm, place a shop towel around the control arm to avoid damaging the control arm.
4. Check the taper and thread of the ball stud and ball joint for any damage. No damage on the control arm is allowed. If a thread is scratched or there is any noticeable damage caused to the tapers as a result of disassembly, the control arm should be replaced.
5. Disassemble the small clamping ring.
1. Using your fingers, gently roll the small clamp ring up and over the boot lip.
2. Discard the small clamp ring.
Note
It is recommended that a 6 mm (1/4 in) screwdriver blade be modified as pictured to assist with this task.
6. Disassemble the big clamping ring and remove the sealing boot.
Using a suitable tool, pull the big clamp ring and sealing boot up and away from the arm.
Note
Care must be taken to avoid scratching the machined surfaces of the housing and ball stud. Minor scratches and damage will cause premature failure. Discard the old boot and large clamp ring.
7. Remove the boot from the ball joint.
8. Using a clean, flat-bladed screwdriver or similar tool, scoop any grease from inside the removed boot and apply it to the open end of the ball joint housing.
9. Assemble the small clamping ring to the new sealing boot.
1. Use clean fingers to assemble a new small clamp ring onto the new sealing boot.
2. Check that the small clamping ring seats smoothly into the boot lip.
3. Inspect the internal surfaces of the boot to ensure that they are free of contamination.
10. Assemble the sealing boot with the small clamping ring to the control arm.
1. Assemble the sealing boot and small ring assembly over the ball stud.
2. Ensure that the large end of the boot seats in the housing groove.
3. Check the assembly for any damage.
Note
Apply a small amount of grease to the tapered end of the J-46620 tool (1) to aid in sliding the big clamping ring (4) into position on the tool. Install the clamping ring onto the J-46620 tool using external snap ring pliers (3) or equivalent and a hammer (5). Use the hammer (5) to move the clamping ring (4) over the tapered end of the tool (1). Use the second part of the J-46620 tool (2) to slide the clamping ring (4) over the ball joint boot.
11. Using J-46620 tool, install the big clamping ring into the correct position. It is essential that the clamp ring is not over-extended.
1. Slide the big clamping ring over the tool and into position.
2. Check that the ring is not twisted and fits smoothly over the boot.
3. Check that no damage has been caused.
12. Inspect the big clamp ring. Make sure that the position of the coil end is at 90 or 270 degrees to the length of the control arm. If the clamp ring is incorrectly indexed, it may interfere with the movement of the ball joint.
13. Complete a final inspection of the ball joint assembly.
1. Inspect the thread and taper. Check for damage or galling.
2. Ensure that the small clamping ring fits smoothly without folds or pinching.
3. Inspect the sealing boot. Ensure that there are no folds or boot damage.
4. Inspect the big clamping ring. Ensure that the ring is not twisted or damaged and that it is installed correctly.
5. Inspect the whole control arm for damage.
14. Install the control arms. Refer to Control Arm Replacement and Front Lower Control Arm Replacement in SI.
15. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
16. Perform a front wheel alignment. Refer to Wheel Alignment in SI.