Control Arm Bushing - Front Lower

This procedure covers removal and replacement of the front lower control arm bushings on a 2009 Aston Martin DB9, including disassembly of suspension components and pressing out/in the bushings.

Warnings

Tools required

Parts

• Front lower control arm bushing kit × 2 — Use OEM specification
• Lower ball joint cotter pin × 2 — Use OEM specification
• Thread locking compound (medium strength) × 1 — Loctite 243 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at manufacturer-specified jacking points
4. Remove front wheels completely
5. Spray all suspension fasteners with penetrating oil and allow 15-20 minutes to soak
6. Verify you have correct replacement bushings for front lower control arm (inner and outer positions)

Procedure

1. 1

   Disconnect sway bar end link from control arm
   Locate the sway bar end link connecting to the front lower control arm. Hold the shaft of the end link with an Allen key to prevent rotation, then remove the nut securing the link to the control arm. Separate the end link from the control arm mounting point. The link will remain attached to the sway bar.
2. 2

   Remove lower ball joint cotter pin and nut
   Locate the lower ball joint where it connects to the steering knuckle/upright. Verify the ball joint retention method against Aston Martin factory documentation before proceeding, as the DB9 typically does not use a castellated nut with cotter pin. Remove the retaining fastener but do not fully separate the joint yet. the lower ball joint where it connects to the steering knuckle. Identify the ball joint retention method used on this vehicle (castellated nut with cotter pin, or pinch bolt) per Aston Martin service documentation. Remove the retaining fastener but do not fully separate the joint yet.
3. 3

   Separate ball joint from knuckle
   Using a press-type ball joint separator tool, separate the lower ball joint stud from the steering knuckle. Avoid pickle forks, which will tear the ball joint boot and can damage the aluminum components. Position the separator between the control arm ball joint mounting boss and the knuckle, then apply pressure until the taper releases. The control arm will drop down once separated. Support the control arm with a jack or block if needed to control descent. Note: Using a press-type ball joint separator tool (avoid pickle forks which can damage boots and aluminum components), separate the lower ball joint stud from the steering knuckle.
   ⚠Ball joint may release suddenly under pressure. Keep hands clear of pinch points between control arm and knuckle.
4. 4

   Remove front control arm mounting bolt
   Locate the front control arm mounting bolt that passes through the forward bushing. This bolt secures the control arm to the front subframe mounting bracket. Remove this bolt completely and retain for reinstallation. Verify the fastener head type before beginning; this bolt may be a hex-head or Torx fastener depending on build. Note the orientation of any washers or spacers. Note: Remove this bolt completely. Verify fastener head type and whether the bolt is a single-use stretch bolt requiring replacement per Aston Martin service documentation before reinstalling. Note the orientation of any washers or spacers. Note: Note the fastener head type and obtain the correct tool; verify against OEM documentation.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that passes through the rear bushing. This bolt secures the control arm to the subframe at its rearward mounting point. Remove this bolt completely. With all control arm pivot fasteners removed, carefully lower and remove the control arm from the vehicle. Verify the number and location of pivot bushings against Aston Martin documentation, as the DB9 lower arm configuration may differ from a simple two-bolt layout. Note the position and orientation of the control arm for reinstallation.
6. 6

   Inspect control arm and bushing bores
   With the control arm removed, inspect the bushing mounting bores for damage, corrosion, or elongation. Inspect the control arm for cracks, particularly around the ball joint mounting point and bushing eyes. Clean the bushing bores thoroughly with a wire brush. If the control arm shows structural damage, replacement of the entire arm is required rather than just bushing replacement.
7. 7

   Press out old bushings
   Position the control arm in a hydraulic press with appropriate support under the control arm body. Using a bushing removal adapter sized for the bushing outer diameter, press out the old front bushing from the control arm. Repeat for the rear bushing. The bushings are interference-fit and will require significant force to remove. Ensure the press ram is centered on the bushing sleeve to avoid damaging the control arm bore.
8. 8

   Clean bushing bores and prepare for installation
   Thoroughly clean the bushing bores in the control arm, removing all rubber residue, dirt, and corrosion. Inspect the bore surfaces for scoring or damage. Apply a light coat of rubber assembly lubricant or soapy water to the new bushing outer diameter and the control arm bore to ease installation. Do not use petroleum-based lubricants as they can degrade the bushing rubber.
9. 9

   Press in new bushings
   Position the new front bushing at the control arm bore, ensuring correct orientation (any voids or flats in the bushing must align with control arm design). Using the hydraulic press with a properly sized installation adapter, press the bushing into the bore until it is fully seated and flush with the control arm surface. The bushing outer sleeve should be centered in the bore. Repeat for the rear bushing, verifying correct orientation before pressing.
10. 10

    Install control arm to subframe
    Position the control arm into the subframe mounting brackets, aligning the new bushings with the mounting bolt holes. Insert the front mounting bolt through the bushing and subframe bracket, threading it by hand. Insert the rear mounting bolt through the rear bushing and bracket. Do not torque these bolts yet - leave them finger-tight plus 1-2 turns. The final torque must be applied with the suspension at ride height.
11. 11

    Connect ball joint to knuckle
    Raise the outer end of the control arm to align the ball joint stud with the hole in the steering knuckle. You may need to use a jack under the control arm to lift it into position. Insert the ball joint stud into the knuckle taper and install the retaining fastener appropriate to this vehicle (self-locking nut, pinch bolt, or castellated nut per factory documentation). Tighten to specification. If a castellated nut and cotter pin are used, install a new cotter pin and bend the ends to secure. Note: Insert the ball joint stud into the knuckle taper and install the retaining fastener appropriate to this vehicle. Tighten to specification per Aston Martin documentation. If a castellated nut and cotter pin are used, advance to the next castle slot if needed to align with the cotter pin hole and install a new cotter pin, bending the ends to secure.
    Torque spec

    Lower Ball Joint Nut60 Nm (44 lb-ft)
12. 12

    Reconnect sway bar end link
    Position the sway bar end link ball stud into the control arm mounting hole. Install the retaining nut onto the stud. Hold the end link shaft with an Allen key to prevent rotation, then torque the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Install wheels and lower vehicle
    Reinstall the front wheels, threading the lug nuts by hand to ensure proper seating. Tighten lug nuts in a star pattern to approximately 50% of the factory-specified final torque value (verify lug nut torque against Aston Martin documentation for the 2009 DB9). Carefully lower the vehicle until the tires contact the ground and the suspension is at normal ride height, but keep the jack in place supporting some weight. This simulates the loaded condition required for control arm bolt torquing.
14. 14

    Torque control arm mounting bolts at ride height
    With the vehicle weight on the suspension (wheels on ground or equivalent load), torque both the front and rear control arm mounting bolts to specification. This is critical - torquing with the suspension hanging will preload the bushings incorrectly and cause premature failure. Access may require working from under the vehicle with the jack providing minimal lift for clearance.
    ⚠Control arm bolts must be torqued with vehicle weight on suspension. Failure to do so will cause bushing binding and premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
15. 15

    Final torque wheel lug nuts
    With the vehicle fully lowered and weight on all wheels, perform final torque of the wheel lug nuts in a star pattern to specification. Double-check that all fasteners have been reinstalled and torqued properly.
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)

Reassembly

1. Reassembly is covered in the procedure steps above
2. Ensure all cotter pins are new and properly installed with ends bent for security
3. Verify all suspension fasteners are torqued to specification
4. Control arm mounting bolts must be torqued at ride height - this is critical for bushing longevity

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering response and absence of looseness or wandering
• After 50-100 miles, re-check torque on all suspension fasteners installed during this procedure
• Have front wheel alignment checked and adjusted by a qualified shop, as suspension disassembly will have altered toe and camber settings
• Inspect for any fluid leaks that may have occurred from disturbing nearby components

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