2016 Sienna Front Knuckle Assembly

Replacing a front knuckle assembly on a 2016 Sienna can be a daunting task, but with the right tools and knowledge, it can be accomplished successfully. This comprehensive guide will provide step-by-step instructions, accompanied by detailed images, to ensure a smooth and efficient replacement process.

To begin, it is crucial to gather the necessary tools, including a socket wrench set, torque wrench, ball joint separator, and a new knuckle assembly. Safety should always be prioritized, so ensure that the vehicle is properly secured and the parking brake is engaged. Additionally, disconnecting the negative terminal of the battery is essential to prevent any electrical hazards.

The replacement process commences with removing the wheel and accessing the knuckle assembly. Using a socket wrench, carefully detach the caliper bracket and hang it securely with a wire. Next, disconnect the ball joint by leveraging a ball joint separator. Finally, remove the axle nut and separate the axle from the knuckle assembly. Upon completing these steps, the old knuckle assembly can be replaced with the new one, followed by reattaching all the removed components in reverse order.

Required Tools And Materials

To replace the 2016 Sienna front knuckle assembly, you will need the following tools and materials:

Tools:

– 19mm socket
– 21mm socket
– 17mm socket
– 14mm socket
– 12mm socket
– Ratchet
– Breaker bar
– Torque wrench
– Jack and jack stands
– Pry bar
– Hammer
– Chisel

Materials:

– New front knuckle assembly
– Brake pads
– Brake rotors
– Brake calipers
– Brake caliper bolts
– Brake line bolts
– ABS sensor bolts
– Tie rod end bolts
– Ball joint bolts
– Sway bar link bolts

Detailed Tools List:

Tool	Description
19mm socket	Used to remove the lug nuts and caliper bolts
21mm socket	Used to remove the axle nut
17mm socket	Used to remove the tie rod end bolts and ball joint bolts
14mm socket	Used to remove the brake line bolts and ABS sensor bolts
12mm socket	Used to remove the sway bar link bolts
Ratchet	Used to turn the sockets
Breaker bar	Used to break loose the axle nut
Torque wrench	Used to tighten the bolts to the proper torque

Removing The Brake Caliper And Rotor

Step 1: Support the vehicle and remove the wheel

Park the vehicle on a level surface and engage the parking brake. Loosen the lug nuts on the front driver’s side wheel, then use a jack and jack stands to safely support the vehicle. Remove the lug nuts and the wheel.

Step 2: Disconnect the brake line from the caliper

Locate the brake line connected to the caliper. Carefully place a catch pan underneath to collect any brake fluid that may leak out. Use a wrench to loosen the banjo bolt that connects the brake line to the caliper. Disconnect the brake line and plug the opening with a rubber cap.

Step 3: Remove the caliper from the knuckle

Locate the two bolts that secure the caliper to the knuckle. Use a wrench or a socket to remove these bolts. Carefully lift the caliper off the knuckle and hang it securely out of the way with a bungee cord.

Step 4: Remove the brake rotor

The brake rotor is held in place by two bolts. Locate and remove these bolts, then carefully lift the rotor off the hub.

Step 5: Clean and inspect the caliper, rotor, and hub

Before reinstalling the new knuckle assembly, it is important to thoroughly clean and inspect the caliper, rotor, and hub. Use a wire brush or brake cleaner to remove any dirt or debris from the caliper and rotor. Inspect the caliper for any signs of damage, leaks, or wear. Inspect the rotor for any cracks, gouges, or excessive wear. If the caliper or rotor is damaged or worn, it should be replaced before reinstalling the knuckle assembly.

Caliper Inspection	Rotor Inspection
Check for leaks	Look for cracks
Inspect the piston	Note any gouges
Examine the guide pins	Verify even wear

Removing The Ball Joint

The ball joint connects the steering knuckle to the lower control arm. It allows the wheel to turn left and right. To remove the ball joint, you will need a ball joint separator.

1. Place the ball joint separator on the ball joint.

2. Tighten the ball joint separator until the ball joint pops out of the steering knuckle.

3. Remove the ball joint from the steering knuckle.

To make the process more detailed:

1. Locate the ball joint on the steering knuckle. It is a round metal joint with a rubber boot around it.

2. Clean the area around the ball joint with a wire brush to remove any dirt or debris.

3. Place the ball joint separator on the ball joint. The ball joint separator should have two forks that fit around the ball joint.

4. Tighten the ball joint separator until the ball joint pops out of the steering knuckle. You may need to use a hammer to tap the ball joint separator to get it to pop out.

5. Remove the ball joint from the steering knuckle once it has popped out.

6. Inspect the ball joint for any damage. If the ball joint is damaged, it will need to be replaced.

Ball Joint Damage	Cause	Symptoms
Torn boot	Wear and tear, exposure to the elements	Grease leaking out of the boot, clicking or popping noise when turning
Loose or worn ball joint	Excessive wear, impact damage	Loose steering, clunking noise when driving over bumps
Damaged ball joint stud	Impact damage, overtightening	Difficulty turning the wheel, vibration while driving

Replacing 2016 Sienna Front Knuckle Assembly

Extracting The Old Knuckle Assembly

Step 1: Safety first. Park the Sienna on a flat, stable surface and engage the parking brake.

Step 2: Remove the wheel and tire assembly.

Step 3: Remove the brake caliper and hang it securely using a bungee cord or wire.

Step 4: Remove the brake rotor.

Step 5: Disconnect the ball joint from the knuckle assembly.

Step 6: Remove the tie rod end from the knuckle assembly.

Step 7: Locate and remove the 4 bolts that secure the knuckle assembly to the suspension. These bolts are typically 17mm or 19mm in size.

Detailed Explanation of Step 7:

a) The knuckle assembly is secured to the suspension by four bolts. These bolts are located on the back side of the knuckle assembly.
b) Use a wrench or socket to remove the bolts. Be careful not to strip the bolt heads.
c) Once the bolts are removed, the knuckle assembly will come loose from the suspension.
d) Carefully remove the knuckle assembly from the vehicle.

Step 8: Clean the mating surfaces of the knuckle assembly and the suspension.

Step 9: Prepare to install the new knuckle assembly.

Installing The New Knuckle Assembly

With the old knuckle assembly removed, it’s time to install the new one. Here’s how to do it:

1. Clean the Mounting Surface

Before installing the new knuckle assembly, clean the mounting surface on the steering knuckle. This will ensure a proper fit and prevent any debris from getting trapped between the two surfaces.

2. Install the Knuckle Assembly

Gently lift the new knuckle assembly into place and align it with the mounting bolts. Start tightening the bolts by hand, then torque them to the specified specifications using a torque wrench.

3. Install the Brake Caliper

Install the brake caliper onto the knuckle assembly and secure it with the mounting bolts. Torque the bolts to the specified specifications.

4. Install the Brake Rotor

Slide the brake rotor onto the wheel hub and secure it with the lug nuts. Torque the lug nuts to the specified specifications.

5. Install the Wheel

Install the wheel onto the hub and tighten the lug nuts by hand. Then, use a torque wrench to torque the lug nuts to the specified specifications.

6. Connect the Brake Line

Connect the brake line to the brake caliper and tighten the fitting securely.

7. Bleed the Brakes

After connecting the brake line, bleed the brakes to remove any air from the system.

8. Tighten the Ball Joint Nuts

Tighten the ball joint nuts to the specified torque. To properly torque the upper and lower ball joint nuts, you may need to use a special tool called a torque multiplier. This tool will help you apply the necessary force to achieve the correct torque without damaging the nuts.

9. Double-Check Everything

Double-check all bolts and nuts to make sure they are properly tightened. Check the brake fluid level and top it off if necessary.

Reassembling The Brake Components

9. Reinstall the brake caliper bracket

Apply a thin layer of brake caliper grease to the back of the brake caliper bracket.
Position the brake caliper bracket over the brake rotor and secure it with the two M14 bolts. Tighten the bolts to 140 ft-lbs.

10. Reinstall the brake caliper

Apply a thin layer of brake caliper grease to the slide pins on the brake caliper.
Position the brake caliper over the brake rotor and secure it with the two M12 bolts. Tighten the bolts to 80 ft-lbs.

11. Connect the brake hose

Lubricate the threads on the brake hose fitting with brake fluid.
Screw the brake hose fitting into the brake caliper and tighten it to 15 ft-lbs.

12. Bleed the brakes

Connect a brake bleeder wrench to the bleeder screw on the brake caliper.
Open the bleeder screw and allow the brake fluid to flow out until it is clear of air bubbles.
Close the bleeder screw and repeat the process on the other side of the vehicle.

13. Inspect the brake system

Check the brake fluid level and fill it to the correct level if necessary.
Check for any leaks in the brake system.
Test the brakes by driving the vehicle and making sure that they are operating properly.

Tightening Of Bolts And Final Inspection

Once the new knuckle assembly is in place, it is important to tighten all of the bolts to the proper specifications. The torque specifications for the bolts can be found in the Toyota Sienna service manual. Once all of the bolts are tightened, the final inspection can be performed.

The final inspection should include checking for any leaks, loose bolts, or other damage. The brakes should also be tested to ensure that they are working properly. If any problems are found, they should be corrected before driving the vehicle.

Here are the detailed steps for tightening the bolts and performing the final inspection:

Use a torque wrench to tighten all of the bolts to the specified torque. The torque specifications are as follows:

Bolt	Torque
Strut-to-knuckle bolts	135 ft-lb (183 N·m)
Ball joint-to-knuckle bolts	95 ft-lb (129 N·m)
Control arm-to-knuckle bolts	145 ft-lb (197 N·m)

Check for any leaks by looking for fluid on the ground or on the components. If any leaks are found, they should be repaired before driving the vehicle.
Check for any loose bolts by shaking the components and checking for any movement. If any loose bolts are found, they should be tightened to the proper torque.
Check for any other damage by visually inspecting the components. If any damage is found, it should be repaired before driving the vehicle.
Test the brakes to ensure that they are working properly. The brakes should be able to stop the vehicle without any pulling or vibration.

How To Replace 2016 Sienna Front Knuckle Assembly

1. Safety first! Park your Sienna on a level surface and engage the parking brake. Allow the engine to cool completely before beginning any work.

2. Locate the front knuckle assembly. It is the large, cast-iron component that connects the wheel hub to the suspension.

3. Remove the cotter pin from the castle nut on the ball joint.

4. Use a ball joint separator to separate the ball joint from the knuckle assembly.

5. Remove the two bolts that secure the knuckle assembly to the suspension.

6. Carefully pry the knuckle assembly away from the suspension.

7. Inspect the knuckle assembly for any damage. If there is any damage, it will need to be replaced.

8. Install the new knuckle assembly by reversing the steps above.

9. Tighten the bolts to the specified torque.

10. Install the cotter pin in the castle nut on the ball joint.

11. Double-check all of your work before driving the Sienna.

3 Steps to Replace 2016 Sienna Front Knuckle Assembly