Control Arm Bushing - Front Upper

This procedure covers removal and replacement of the front upper control arm bushings on a 2009 Aston Martin DB9, requiring suspension disassembly and specialized bushing press tools.

Warnings

Tools required

Parts

• Front upper control arm bushing × 2 — Use OEM specification
• Upper ball joint cotter pin (if equipped) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at manufacturer-approved jacking points
5. Remove front wheels completely

Procedure

1. 1

   Access upper control arm area
   Remove the front wheel arch liner or splash shield to access upper control arm mounting points. Identify the liner fasteners (verify exact count and type against Aston Martin factory documentation — commonly a mix of plastic push-rivets/clips and screws); remove all fasteners and carefully pull liner away to expose upper suspension components. The upper control arm will be visible above the steering knuckle.
2. 2

   Support lower suspension
   Position a floor jack under the lower control arm near the ball joint to support the suspension assembly. Raise jack just enough to take light load off the upper control arm. This prevents the suspension from dropping when the upper ball joint is disconnected.
3. 3

   Disconnect upper ball joint from knuckle
   Remove the cotter pin from upper ball joint castle nut if equipped. Remove the upper ball joint nut completely. Use a proper ball joint separator tool to break the taper connection between ball joint stud and steering knuckle. Avoid pickle forks, which can damage the aluminum knuckle and ball joint boot. Strike or torque the tool firmly but do not damage threads. Once separated, push the ball joint stud down and out of the knuckle. Strike the tool firmly but do not damage threads. Once separated, push the ball joint stud down and out of the knuckle. Note: Remove the upper ball joint retaining fastener (verify whether DB9 uses a castle nut with cotter pin or a pinch/clamp bolt at the knuckle per OEM manual). Use a proper ball joint separator tool (avoid a pickle fork on aluminum components to prevent boot and knuckle damage) to break the taper connection between ball joint stud and steering knuckle. Once separated, push the ball joint stud out of the knuckle. Note: Verify the upper ball joint attachment method against Aston Martin factory documentation before proceeding, as the DB9 upper ball joint may be integral to the control arm and bolt to the knuckle rather than use a tapered stud. If a tapered stud is confirmed, use a proper ball joint separator tool (not a pickle fork, which can damage the aluminum components) to break the taper connection, taking care not to damage threads.
   Torque spec

   Upper Ball Joint Nut50 Nm (37 lb-ft)
4. 4

   Mark control arm position
   Before removing mounting bolts, use a paint marker or scribe to mark the control arm position relative to the chassis mounting bracket. This ensures proper alignment during reinstallation and maintains suspension geometry.
5. 5

   Remove control arm mounting bolts
   Locate the front and rear control arm mounting bolts that attach the arm to the chassis. Verify the fastener head type for the upper control arm chassis bolts against the Aston Martin workshop manual before selecting tools. Remove both mounting bolts completely and carefully lower the control arm from the vehicle. Note the position of any shims or washers for reinstallation. Note: Locate the front and rear upper control arm mounting bolts that attach the arm to the chassis (verify head type per OEM manual; do not assume Torx). Remove both mounting bolts and carefully lower the control arm from the vehicle. Carefully note the exact position and quantity of any alignment shims or cam washers, as these set camber/caster and must be reinstalled identically. Note: Verify the mounting bolt head type and size against factory documentation before selecting tools, as these may be hex-head or another type rather than Torx; do not assume a specific drive type.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Inspect control arm and bushings
   With control arm removed, thoroughly inspect the bushing bores for cracks, corrosion, or damage. Clean the bushing mounting areas with a wire brush. Check the ball joint for excessive play or torn boots. The bushings will be visible as rubber or polyurethane components pressed into the control arm mounting eyes.
7. 7

   Press out old bushings
   Verify that the front upper control arm bushings are serviceable separately on the 2009 DB9; many Aston Martin control arms are supplied only as complete assemblies. If serviceable, use a hydraulic press with appropriate bushing removal adapters to press the old bushings out of the control arm. Support the control arm on the press bed with the bushing eye aligned over an opening. Apply steady pressure to push the bushing through. The inner metal sleeve may come out with the bushing or require separate removal. Repeat for both front and rear bushings. Note: Confirm with Aston Martin factory documentation whether the front upper control arm bushings are individually serviceable on this vehicle, as the arm may only be supplied as a complete assembly. If serviceable, use a hydraulic press with appropriate bushing removal adapters to press the old bushings out of the control arm.
8. 8

   Clean bushing bores
   Thoroughly clean the control arm bushing bores using a wire brush and solvent. Remove all rust, old rubber residue, and debris. Inspect bores for damage or deformation. The bore must be clean and smooth for proper new bushing installation.
9. 9

   Press in new bushings
   Apply a light coat of assembly lubricant to the outer diameter of the new bushings and inside the control arm bores. Position the new bushing squarely in the bore, verifying against OEM documentation whether the bushing has directional voids or offset positioning that must align to a specific orientation before pressing. Using the hydraulic press with proper adapters, press the bushing fully into the bore until it seats flush or to the specified depth. Press slowly and ensure the bushing enters straight. Repeat for both bushings.
10. 10

    Install control arm to chassis
    Position the control arm back into the chassis mounting brackets, aligning with the marks made during removal. Insert the front and rear mounting bolts with any original shims or washers in their correct positions. Thread bolts in by hand first to ensure proper alignment. Do NOT torque bolts at this stage - they must be torqued with vehicle weight on suspension.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Connect upper ball joint to knuckle
    Clean the ball joint stud taper and knuckle bore with solvent and a wire brush. Position the ball joint stud into the knuckle bore, ensuring full engagement. Install the ball joint retaining nut and tighten to the OEM-specified torque. Confirm fastener type per OEM manual — if a prevailing-torque/self-locking nut is used it must be replaced new; if a castle nut with cotter pin is used, align the slots and fit a new cotter pin, bending the ends to secure. Note: Install a new ball joint nut (self-locking nut if so equipped; castle nut with new cotter pin only if the vehicle actually uses one) and tighten to specification. Verify the correct nut type against the Aston Martin workshop manual. Note: Install the retaining nut (verify whether it is a castle nut with cotter pin or a self-locking nut that must be replaced) and tighten to specification.
    Torque spec

    Upper Ball Joint Nut50 Nm (37 lb-ft)
12. 12

    Reinstall wheel arch liner
    Reposition the front wheel arch liner or splash shield. Install all fasteners (push-rivets/clips and screws as applicable) in their original locations, ensuring the liner is properly seated and does not interfere with suspension travel or steering components.
13. 13

    Install wheel and lower vehicle
    Install the front wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but full weight is not yet on the suspension. This is the point where control arm bolts must be torqued.
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)
14. 14

    Torque control arm bolts at ride height
    With the vehicle at normal ride height (wheels touching ground with vehicle weight on suspension), torque the front and rear upper control arm mounting bolts to specification. This is critical - torquing these bushings in an unloaded position will cause premature bushing failure and binding. After torquing, fully lower the vehicle to the ground.
    Torque spec

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

    Final torque wheel lug nuts
    With vehicle fully on the ground, torque wheel lug nuts to specification in a star pattern. Repeat procedure for opposite side if necessary.
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)

Reassembly

1. Reassembly follows removal in reverse order with critical attention to torquing control arm bolts only at ride height
2. Use new cotter pins if equipped on ball joint castle nuts
3. Ensure all wheel arch liner fasteners are reinstalled to prevent component damage from debris

Verification

• Test drive vehicle at low speed and check for unusual noises, vibrations, or steering pull
• Bounce front suspension by hand to verify no clunking or looseness from control arm area
• Schedule four-wheel alignment as suspension geometry has been disturbed
• Recheck control arm bolt torque after 50-100 miles of driving

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