KTI Off Road

As you may have noticed some time ago we figured that worn out ball joints in our XJ are a reason for annoying death wobble constantly bugging our car. Recently we got some queries about how difficult this task is to perform by average garage mechanic, so here it is – small how to replace them. this Procedure apply to all Jeeps that have front Dana 30 axle: Cherokees (XJ), Grands (ZJ) and Wranglers. Probably more or less to any car, but I didn’t try it there so no warranties.

First, before you even start a list of special tools you will definitely need. All of them usually can be rented out from your local parts store. You will need tie rod end separator, good torque wrench, ball joint replacement set and a slide hammer. Be prepared for leaving there quite a nice deposit – but it will motivate you to finish the job quicker and get your deposit back sooner .

To make things easier and faster jack your car up and take off both front wheels. Safety first – chock your rear wheels and use good jack stands to hold your front up in the air.

Then unbolt brake caliper (12mm bolts shown on the picture) and carefully hand them somewhere out of your way.

Be careful not to stretch (nor hang them by) brake lines.

Then disconnect tie rod end from the knuckle itself:

our steering setup is a little bit different than stock one (it’s upgraded to the 1 ton version) but it works the same way – take off the nut and carefully (use tie rod end removing tool) pry it out from the knuckle.

Then unbolt three 12 point 13 mm bolts holding axle hub to the knuckle. Here you can see two of them – the third one is on the other side of hub (behind the axle from this view).

Taking out hub can be a little painful job, but nothing than can’t be done using slide hammer.

No we can get to the real jog. After getting off bolts from both upper and lower joints:

and then using ball joint separator and quite a heavy hammer pry off steering knuckle from them:

After couple of heavy hits you should end up with this nice view:

Here is where the real fun begins. Using ball joint press you have to carefully press out first upper ball joint:

and then using hole after it you can get to the lower one:

Now before you put new ones on make sure that you carefully clean the seats for new ones – use fine grit paper or even better – steel wool.

After this carefully press in new ball joints starting from lower one (yup you still need this upper hole) and then upper one.

Now when you have new shiny ball joints in place:

you can start installation procedure in revers order:

- put the steering knuckle on, carefully tighten nuts to the specification and lock them inplace using new cotter pins

- insert the axle shaft in and tighten three 12 point 13 mm bolts to 75 ft lbs

- connect tie rod end a d tighten it’s nut to 55 ft lbs

- put the brake rotor back on and bolt on the caliper

- move to the other side.

After you’re done with both sides put your wheels back on. Test your brakes before you move as they probably will need two or three strokes before they start working after taking out and putting on both front calipers. Make a test drive to your party store to get back your deposit .

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