How to Replace Steering Knuckle 00-04 Ford Focus
Difficulty: Advanced · About 120 min · Ford Focus
Replace a front steering knuckle on a 2000–2004 Ford Focus, separating the brakes, axle, tie rod, ball joint, and strut, then restoring the ABS wiring and checking front alignment.
Tools you will need
- Torque Wrench
- 15mm Socket
- Pry Bar
- 16mm Socket
- Jack Stands
- 19mm Socket
- 7mm Hex Wrench
- T50 Socket
- 32mm Socket
- Ratchet
- Floor Jack
- 1/2 Inch Breaker Bar
Parts and supplies
- Front steering knuckle
- Axle nut and cotter pin
- Brake pads
Steps
Raise the vehicle and remove the wheel
Loosen the lug nuts and axle nut with the vehicle on the ground. Raise and support the front securely, then remove the wheel.
Remove the caliper and rotor
Remove the caliper slider fasteners and retaining clip, then lift the caliper away and support it so the hose is not stretched. Remove the pads and rotor.
Separate the tie rod and ball joint
Remove the tie rod nut and separate the joint with an approved separator. Remove the lower ball joint pinch fastener and free the joint from the knuckle without damaging its boot.
Remove the axle and knuckle
Free the axle splines from the hub while supporting the axle, then remove the strut pinch bolt. Work the knuckle off the lower strut and keep the ABS sensor wire clear of the work area.
Install the replacement knuckle
Compare the replacement with the original and transfer any required dust shield or sensor. Guide the axle through the hub, align the lower ball joint and strut, and install the pinch hardware by hand.
Reconnect suspension and steering
Reinstall the strut pinch bolt, ball joint fastener, and tie rod nut, tightening each to the vehicle's specification. Fit the axle nut and its locking hardware as directed by the service manual.
Reinstall the brakes and wheel
Refit the rotor, pads, retaining clip, and caliper. Tighten the brake fasteners and axle nut to the specified values, then reinstall and torque the wheel fasteners in a star pattern.
Check the ABS system and alignment
Pump the brake pedal until firm, route the ABS wire through all original clips, and confirm the warning lamp performs its normal self-check. Have alignment checked before normal driving and test cautiously.
Check your vehicle’s repair manual for exact specifications and fit.