Front Suspension: Removal & Installation Honda Pilot I

Removal & Installation

1. Screw the ball joint thread protector all the way onto the ball joint stud. (Scheme 4)
2. Apply molybdenum grease to the ball joint remover. (Scheme 5) This makes installing the tool easier and prevents damage to the pressure bolt threads.
3. Install the ball joint remover. (Scheme 6) Insert the jaws carefully, making sure you do not damage the ball joint boot. Adjust the jaw spacing by turning the pressure bolt.
4. Once the ball joint remover is in place, turn the adjusting bolt (A) as necessary to make the jaws parallel. (Scheme 7) Then hand-tighten the pressure bolt (B), and recheck the jaws to make sure they are still parallel.
5. After making the adjustment to the adjusting bolt, make sure the head of the adjusting bolt (A) is in this position to allow the jaw (C) to pivot.
6. Tighten the pressure bolt (A). (Scheme 8) See «TORQUE SPECIFICATIONS»(ref-166438-S04903121152004092000000). If the ball joint does not pop loose, strike the side of the knuckle with a hammer and the ball joint striker to dislodge the ball joint.
7. Remove the tool. Then remove the thread protector from the end of the ball joint, and pull the ball joint out of the steering/suspension arm. Inspect the ball joint boot, and replace it if damaged.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Remove the boot clip and the boot.
2. Pack the interior of the boot and lip (A) with grease. See. DO NOT contaminate the lower collar of the boot (B) with grease. (Scheme 9)
3. Wipe the grease off the tapered portion of the shaft, and pack fresh grease into the base. DO NOT let dirt or other foreign materials get into the boot.
4. Install the boot onto the ball joint, then squeeze it gently to force out any air.
5. Adjust the ball joint boot clip guide with the adjusting bolt (B) until its base is just above the groove around the bottom of the boot. (Scheme 10) Then slide the clip (A) over the tool and into position on the boot.
6. After installing a boot, wipe any grease off the exposed portion of the ball joint pin.

Scheme 9

Scheme 10

1. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels.
2. Remove the flange nuts (A) while holding the respective joint pins (B) with a hex wrench (C), and remove the stabilizer link (D). (Scheme 11)
3. Install the stabilizer link (A) on the stabilizer bar (B) and damper (C) with the joint pins (D) set at the center of each moving range. (Scheme 12)
4. Install the flange nuts, and lightly tighten them.
5. Place a jack under the lower arm, and raise the suspension to load it with the vehicle's weight.
6. Tighten the flange nuts (A) to specification while holding the respective joint pins (B) with a hex wrench (C). (Scheme 11)

Scheme 11

Scheme 12

Removal

1. Raise the vehicle, and support it with safety stands in the proper locations.
2. Remove the front wheels.
3. Remove the damper. Remove the wheel sensor wire (A) from the damper (B). (Scheme 14) DO NOT disconnect the wheel sensor. Remove the brake hose bracket (C) from the damper. Separate the stabilizer link (D) from the damper. Remove the flange nuts (E) and damper pinch bolts (F) from the damper. NOTE: Damper springs are different, left and right. Mark the springs "L" and "R" before you continue.
4. Remove the service caps (A), and remove the damper by removing the 3 flange nuts. (Scheme 15)

Scheme 13

Scheme 14

Scheme 15

Installation

1. Loosely install the damper (A) onto the frame, then loosely install the 3 flange nuts (B). (Scheme 16)
2. Install the damper. Loosely install the damper pinch bolts (F) and flange nuts (E) to the damper (B). Loosely install the stabilizer link (D) to the damper. Install the brake hose bracket (C) to the damper. Install the wheel sensor wire (A) to the damper.
3. Raise the knuckle with a floor jack until the vehicle just lifts off the safety stand.
4. Tighten the damper pinch bolts and flange nuts.
5. Tighten the flange nut on top of the damper to specification. See «TORQUE SPECIFICATIONS»(ref-166438-S04903121152004092000000).
6. Install the service caps.
7. Install the front wheel.
8. Check the front wheel alignment, and adjust it if necessary. See «WHEEL ALIGNMENT»(ref-166438-S34484684772004092000000).

Scheme 16

1. Raise the front of vehicle, and make sure it is securely supported. Remove the front wheels.
2. Remove the clip (A) from the lower arm ball joint castle nut (B), and remove the nut. see scheme 16 NOTE: DO NOT force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint.
3. Remove the lower arm ball joint from the knuckle using the ball joint remover.
4. Remove the lower arm. Remove the forward lower arm mounting bolt (A). (Scheme 17) Remove the rearward lower arm mounting bolt (B). Remove the lower arm (C) from the subframe.
5. Install the lower arm in reverse order of removal, and note the following items: Be careful not to damage the ball joint boot when connecting the lower arm to the knuckle. Place a jack under the lower arm, and raise the lower arm to load the suspension with vehicle's weight. Tighten all mounting hardware to specification. See «TORQUE SPECIFICATIONS»(ref-166438-S04903121152004092000000). Tighten the castle nut to the lower torque value, then tighten it only far enough to align the slot with the pin hole. DO NOT align the castle nut by loosening it. Install a new clip on the castle nut after tightening. Before installing the wheel, clean the mating surfaces of the brake disc and the inside of the wheel. Check the front wheel alignment, and adjust it if necessary. See «WHEEL ALIGNMENT»(ref-166438-S34484684772004092000000).

Scheme 17