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TSB 02-010-04

Upper Ball Joint Extended Warranty

Visit Geno's Garage for Truck accessories.

Date: December 15, 2004 

Models:

2000 - 2003  (AN)   Dakota 4x2

2000 - 2003  (DN)   Durango 4x2

Overview:
This bulletin involves inspecting and if necessary replacing the Upper ball joints.

NOTE: The upper ball joint warranty period has been extended to 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details.

Discussion:
When diagnosing

Symptom/Condition:
Rear power

Diagnosis:

1.	Position a floor jack under the right side lower suspension arm.
2.	Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire).
3.	Mount a dial indicator (Special Tool C3339 or equivalent) solidly on the upper suspension arm (Fig. 1).
4.	Position the dial indicator plunger against the back side of the Steering knuckle boss for the upper ball joint (Fig. 1).
	1 - RIGHT SIDE BRAKE ROTOR 2 - STEERING KNUCKLE BOSS 3 - UPPER BALL JOINT 4 - DIAL INDICATOR AND       MOUNT CLAMP 5 - UPPER CONTROL ARM 6 - BRAKE HOSE 7 - DIAL INDICATOR PLUNGER Fig. 1 RIGHT SIDE SHOWN (Wheel/Tire Removed For Clarity)
5.	Zero the dial indicator while pulling outward on the top of the tire.
6.	While an assistant watches the dial indicator gauge, grasp the top of the tire and push inward, Record the dial indicator reading observed from the fall outward to full inward position.
7.	Repeat Step #1 through Step #6 on the left side upper ball joint. When both the left and the right upper ball joints have been inspected, proceed to Step #8.
8.	Based on the results recorded in Step #6 a.   Position the dial indicator plunger against the back side of the Steering knuckle boss for the upper ball joint (Fig. 1). b. If the lateral movement on either of the upper ball joints is greater than 0.060 in. (1.52 mm), replace both upper ball joints as described in the Repair Procedure.

Special Tools/Equipment Required:

C-3339A	Set, Dial Indicator (or equivalent)
MS991113	Remover, Tie Rod End (or equivalent)

Parts Required:

Qty.	Part No.	Description
AR (1)	CEXMD471	Package, Upper Ball Joint     Package includes.     2 Upper Ball Joints     6 Bolts     6 Nuts     2 Cotter Pins     2 Castle Nuts

Repair Procedure: 

1.	Raise the vehicle on an appropriate hoist.
2.	Remove the front wheel and tire assemblies.
3.	Position a hydraulic jack under the left side lower control arm and raise the jack to unload the rebound bumper.
4.	the cotter pin from the upper ball joint castle nut.
5.	Remove the upper ball joint castle nut from the upper ball joint stud.
6.	Using a die grinder equipped with a cut-off wheel, grind an "X" through each of the three upper ball joint rivet heads (Fig- 2).
CAUTION: Do not grind into the control arm.
7.	Using an air chisel, chisel the three civet heads off of the upper ball joint.
8.	Punch out the rivets using a drift and hammer.
9.	Separate the upper ball joint from the steering knuckle with special tool MD991113.
10.	Remove and discard the old ball joint.
11.	Using 100 grit emery cloth, lightly sand the top surface of the steering knuckle to remove any rust and/or scale from the steering knuckle (Fig. 3).
	Fig. 2 GRIND BALL JOINT RIVETS 1 - GRIND AN 'X" ON THE TOP OF THE RIVET HEAD 2 - UPPER BALL JOINT Fig. 3 LEFT SIDE SHOWN 1 - UPPER CONTROL ARM 2 - CLEAN SURFACE ON THE STEERING KNUCKLE USING EMERY CLOTH 3 - BRAKE CALIPER 4 - STEERING KNUCKLE 5 - BRAKE ROTOR
12.	Insert the bolts supplied with the ball joint package from the bottom side of the control arm (Fig. 4)
	Fig. BALL JOINT BOLTS 1 - BOLTS AND NUTS 2 - STEERING KNUCKLE
13.	Place the new ball joint onto the control arm and install retaining nuts (Fig. 4). Tighten the nuts to 50 ft. lbs, (68 N-m).
14.	Position the steering knuckle onto the upper ball joint stud.
15.	Install the castle nut onto the ball joint stud. Tighten the upper ball joint castle nut to 60 ft. lbs. (81 N-m).
NOTE: If the castle nut slots do not line up with the cotter pin hole in the ball joint stud, continue tightening the nut until the next set of castle nut slots line up with the cotter pin hole. Do not loosen the nut.
16.	Install a new cotter pin through the castle nut and secure it by bending the arms of the pin.
17.	Install the wheel and tire assembly. Tighten the lug nuts to 100 ft. lbs (135 N-M).
18.	Repeat Step #3 through Step #17 on the right side of the vehicle.
19.	Lower the vehicle.
20.	Place the vehicle on an alignment rack and set toe to + 0.10 degrees (± 0.06 degrees).

Policy:    Reimbursable within the provisions of the extended warranty period of 10 years or 100,000 miles. Refer to Warranty Bulletin D-04-34 for complete details.

Time Allowance:

Failure Code:

This page was edited on: May 3, 2004