Ball Joint - Lower

Remove and replace the lower ball joint on a 2023 Chevrolet Bolt EUV, including disconnecting the steering knuckle and securing the new ball joint with proper torque specifications.

Warnings

Tools required

Parts

• Lower ball joint assembly × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Pinch bolt × 1 — New bolt required

Preparation

1. Park vehicle on level ground and engage parking brake
2. Power down vehicle completely and remove key fob from interior
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at designated lift points
5. Support vehicle securely on jack stands at frame rails
6. Remove wheel completely and set aside
7. Spray all fasteners with penetrating oil and allow 10-15 minutes to soak

Procedure

1. 1

   Disconnect sway bar link if necessary
   If the sway bar link interferes with access to the ball joint, remove the lower sway bar link nut while holding the shaft with an Allen key to prevent rotation. Move the link out of the work area.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Remove ball joint cotter pin
   Locate the ball joint castle nut on the steering knuckle. Use pliers or a cotter pin tool to straighten and remove the cotter pin completely. Discard the old cotter pin as a new one will be installed.
3. 3

   Loosen ball joint castle nut
   Using a 21mm socket, loosen the ball joint castle nut but do not remove it completely. Leave the nut threaded on a few turns to prevent the ball joint stud from suddenly releasing and damaging components.
   ⚠Do not fully remove the nut at this stage. The ball joint taper may release suddenly causing injury or damage.
4. 4

   Separate ball joint from steering knuckle
   Position the ball joint separator tool between the lower control arm and steering knuckle. Apply force to break the taper fit between the ball joint stud and knuckle. Once the taper breaks, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠Tool may slip or release suddenly. Maintain firm grip and keep hands clear of pinch points.
5. 5

   Remove ball joint from control arm
   Depending on ball joint type, remove the fasteners securing the ball joint to the lower control arm. This may be rivets (requiring drilling), bolts, or a press-fit design. For bolted designs, remove the retaining bolts completely. For riveted designs, drill out the rivets per manufacturer specifications. For press-fit designs, use a ball joint press tool to remove the old joint from the control arm.
6. 6

   Clean mounting surfaces
   Use a wire brush to thoroughly clean the ball joint mounting area on the control arm and the taper seat in the steering knuckle. Remove all rust, debris, and old thread locker. Inspect the taper bore in the knuckle for damage or excessive wear.
7. 7

   Install new ball joint to control arm
   Position the new ball joint into the control arm mounting location. For bolted designs, install new bolts and tighten evenly. For press-fit designs, use a ball joint press to seat the new joint fully into the control arm bore until it bottoms out. Ensure the ball joint is oriented correctly with the grease fitting accessible.
8. 8

   Connect ball joint to steering knuckle
   Lift the control arm and align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle completely. Thread the new castle nut onto the ball joint stud by hand, ensuring it threads smoothly without cross-threading.
9. 9

   Torque ball joint castle nut
   Using a calibrated torque wrench and 21mm socket, torque the ball joint castle nut to specification. If the cotter pin holes do not align, tighten the nut further (never loosen) until the next castle slot aligns with the hole in the stud.
   ⚠Never loosen the castle nut to align cotter pin holes. Only tighten to the next alignment point.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin in opposite directions to secure it properly. Ensure the cotter pin is fully seated and cannot work loose.
11. 11

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the control arm or strut. Hold the link shaft with an Allen key and torque the nut to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
12. 12

    Install wheel and lower vehicle
    Mount the wheel onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground but the suspension is not yet loaded. Torque the lug nuts in a star pattern to specification. Then fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification with vehicle weight on wheels where specified
2. Verify cotter pin is properly installed and secured
3. If control arm bolts were disturbed, they must be torqued with vehicle weight on wheels at curb height
4. Check for any tools or parts left in the wheel well before test driving

Verification

• Bounce the front end of the vehicle and listen for any unusual noises from the ball joint area
• Perform a visual inspection to confirm the cotter pin is installed and all fasteners are tight
• Test drive the vehicle at low speed and check for proper steering feel and no clunking noises
• After 50-100 miles, re-torque the ball joint castle nut and verify cotter pin is secure
• Have the front end alignment checked and adjusted as ball joint replacement affects alignment

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