STEP ONE
The first step is to be safe about the project you are about to undertake.Jack up the vehicle and place jack stands under the axel.DO NOT work off the jack or concrete blocks.Its you body you should be protecting.How can you wheel if you are seriously impaired because of careless habits.The placement of jack stands will also make a stable perch so you can get leverage later if needed without the vehicle rocking or swaying.
STEP TWO
Step two is a very simple task.Loosen all lug nuts and remove the tires.At this time you can check your tires for cuts or chunks removed due to the trail or otherwise.You may also want to visually inspect elsewhere since the tire isn't in the way.
STEP THREE
Step three on my Sammy was to remove all 6 bolts holding the entire lockout onto the axel.Some of you may have to remove the lockout part by part.But for my circumstance, the 6 was all that was need to be removed.When the lockout bolts are free, pull the lockout off the axel and set aside.If you had to disasemble the lockout, or not, now would be a good time to clean and lube it up.
STEP FOUR
I revomed the two bolts holding the caliper on and removed the caliper carefully setting it aside and removed the disk.This was a good time to examine the disk and your brake pad situation.Also note if you lines and cracking or worn from tire rubbing.
STEP FIVE
Bend the tabs on the wheel bearing nut keeper and remove both the nut and the keeper.Then remove the inner nut and spacer.This allows access to the outer wheel bearing.Clean and pack to be safe or replace all together.
STEP SIX
Pull the "spindle" out and the rear bearing will be accessible.It may be a chore to get the inner bearing out but since it is all out you might be better off to remove it and clean and repack it.I went ahead and cleaned everything as I went along.
STEP SEVEN
remove the four bolts that hold the disk brake shield onto the knuckle.After the bolts are removed pull the shield off and set aside.
STEP EIGHT
Remove the cotter key and then the castle nut from the tie rod end of the drag link.Use a pickle fork and a hammer to remove this the rest of the way.
STEP NINE
At this time you are able to remove the outer section of the knuckle and have the first view of your birfield.From here you may be able to tell if it is broken or not.As you can see mine was filled up with grease and crap from the trail.
STEP TEN
Mark the top and bottom kingpins to location and placement on the knuckle.Remove the four bolts in each and remove the pins.Note any shims that are in place so that they are put back in the original locations.Be careful not to drop or lose the lower kingpin bearing.Mine fell out before I knew it.
STEP ELEVEN
Remove all 8 bolts that hold the felt gaskets on the back of the knuckle.I had 4 pieces of felt and 2 pieces of metal.These are in 2 pieces so note how they are removed for the correct placement back.
STEP TWELVE
You now may pull the main part of the knuckle off.Look for cracks or fractures.
