|Episode 401: Knight of the Juggernaut|
|Air Date||September 20, 1985|
|Written by|| Burton Armus|
Episode 321: Circus Knight
Episode 402: Kittnap
John Considine as Phillip Nordstrom
Mary Kate McGeehan as Jennifer Knight
Nicholas Worth as Jim Hower
Mary Woronov as Dr. Von Furst
Laurence Haddon as Lloyd
Pamela Susan Shoop as Marta Simmons
Richard Fullerton as Frank
Blair Underwood as Potts
Michael goes to Chicago on an assignment to guard a valuable isotope. Elsewhere, Wilton Knight's daughter, Jennifer unexpectantly suspends FLAG's operations and Michael and KITT find themselves out of a job. Meanwhile, an international terrorist kidnaps Devon Miles and replaces him with a surgically altered impostor as a plot to get his hands on the isotope. Devon's changed behavior alerts Michael's suspicions and he disobeys orders to "take a vacation" until he finds out what is going on. Clues lead to a warehouse, where KITT's Molecular bounded Shell is unknowingly neutralized by a chemical sprayer and he and Michael are attacked by an armored vehicle against whom KITT cannot defend.
KITT is nearly destroyed in the armored car attack, and Bonnie is unable to repair him without Devon Miles' assistance or FLAG's facilities. She and Michael enlist the help of a friendly street kid named RC3, whose gang of friends take KITT to their garage to rebuild him. KITT is reborn with some new gadgets including a rocket-fast "super pursuit" mode. Michael must now race to save the real Devon and prevent the theft of the isotope.
- It was never made clear whether KITT got his MBS back after this episode.