Ball Joints - Upper and Lower

Complete replacement of upper and lower ball joints on the 2023 Chevrolet Bolt EUV, including control arm removal and suspension disassembly.

Warnings

Tools required

Parts

• Upper ball joint × 2 — Use OEM specification
• Lower ball joint × 2 — Use OEM specification
• Cotter pins × 4 — Use OEM specification
• Pinch bolt × 2 — Use OEM specification

Preparation

1. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge.
2. Verify high-voltage system is disabled - consult service manual for proper shutdown procedure.
3. Loosen wheel lug nuts while vehicle is on ground.
4. Raise vehicle on lift or floor jack and support securely on jack stands at manufacturer-specified lift points.
5. Remove front wheels and set aside.
6. Spray all fasteners with penetrating oil and allow to soak for 15 minutes.

Procedure

1. 1

   Disconnect sway bar link
   Remove the sway bar link nut from the control arm. Hold the shaft with an Allen key to prevent spinning while loosening the nut. Disconnect the sway bar link from the control arm and secure it out of the way with wire or zip ties.
   Torque spec

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

   Remove upper ball joint cotter pin and nut
   Straighten and remove the cotter pin from the upper ball joint castle nut using cotter pin removal tool. Remove the ball joint nut completely. Do not reuse the cotter pin.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate upper ball joint from knuckle
   Position ball joint separator tool between the upper control arm and steering knuckle. Apply pressure with the separator to release the ball joint taper from the knuckle. Support the knuckle to prevent dropping once separated. If using pickle fork, be aware this may damage the ball joint boot.
   ⚠Ball joint separator is under high tension. Keep fingers clear of pinch points and wear eye protection.
4. 4

   Remove lower ball joint pinch bolt
   Locate and remove the pinch bolt securing the lower ball joint to the steering knuckle. This bolt passes through a clamping slot in the knuckle. Discard the pinch bolt as a new one must be installed. Support the lower control arm with a floor jack to prevent sudden dropping.
   ⚠Lower control arm is under spring tension. Support with floor jack before removing pinch bolt.
   Torque spec

   Pinch Bolt61 Nm (45 lb-ft)
5. 5

   Separate lower ball joint from knuckle
   With the pinch bolt removed, use a pry bar or light hammer taps to spread the knuckle slot slightly and release the lower ball joint from the knuckle. The knuckle should now be free from both ball joints. Pivot the knuckle assembly outward and support with wire.
6. 6

   Remove control arm mounting bolts (if necessary)
   If ball joints are not serviceable separately, remove the control arm mounting bolts to remove the entire control arm assembly. Note the position and orientation of any alignment shims or cams. Mark control arm position before removal for reference during installation.
   ℹ️Some Bolt EUV configurations may have integrated ball joints requiring full control arm replacement. Verify parts before beginning.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Press out old ball joints
   Secure the control arm in a hydraulic press or ball joint press kit. Position the receiving cup under the ball joint and press adapter on top. Apply steady pressure to press the old ball joint out of the control arm. Clean the ball joint bore thoroughly with a wire brush, removing all rust and debris. Inspect bore for damage.
8. 8

   Press in new ball joints
   Position new ball joint in the control arm bore, ensuring correct orientation (grease fitting accessible, stud pointing correct direction). Use ball joint press to install new ball joint, applying pressure only to the outer housing, never the stud. Press until ball joint is fully seated and flush with control arm surface.
   ⚠Apply press force only to ball joint housing. Pressing on stud will damage internal components.
9. 9

   Install control arm (if removed)
   Position control arm back into mounting location, aligning any shims or cams in their original positions. Install control arm bolts finger-tight only. Do not torque at this time - bolts must be torqued with vehicle weight on wheels.
10. 10

    Connect lower ball joint to knuckle
    Position steering knuckle over lower ball joint stud and align with pinch bolt slot. Ensure ball joint stud is fully seated in the knuckle taper. Install new pinch bolt and torque to specification immediately.
    Torque spec

    Pinch Bolt61 Nm (45 lb-ft)
11. 11

    Connect upper ball joint to knuckle
    Align upper ball joint stud with the hole in the top of the steering knuckle. You may need to use a floor jack under the lower control arm to compress suspension slightly for alignment. Install ball joint castle nut and torque to specification. Align castle nut slots with stud hole - do not back off to align, only tighten further if needed.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Install new cotter pins
    Insert new cotter pins through the castle nut slots and ball joint stud holes. Bend the legs of the cotter pin around the nut to secure. Ensure cotter pin is properly seated and cannot back out.
13. 13

    Reconnect sway bar link
    Position sway bar link back to control arm connection point. Install nut while holding shaft with Allen key. Torque to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
14. 14

    Install wheels and lower vehicle
    Install wheels and hand-tighten lug nuts in star pattern. Lower vehicle until tires just contact ground but suspension is not fully loaded. Torque wheel lug nuts to specification in star pattern. Fully lower vehicle to ground.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Final torque control arm bolts
    With vehicle weight fully on wheels, torque control arm mounting bolts to specification. This is critical for proper bushing alignment and longevity. Bounce suspension several times, then recheck torque.
    ⚠Control arm bolts MUST be torqued with vehicle weight on wheels or premature bushing failure will occur.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Reconnect 12V battery negative terminal.
2. Verify all fasteners have been properly torqued.
3. Check that all cotter pins are installed and properly bent.
4. Ensure no tools or parts were left in wheel wells.

Verification

• Perform visual inspection of all connections and verify cotter pins are installed.
• Test drive vehicle at low speed in safe area and verify no unusual noises or handling issues.
• Schedule 4-wheel alignment immediately - ball joint replacement will affect alignment settings.
• After 50-100 miles, recheck all fastener torque values, especially control arm bolts.
• Monitor for any clunking, popping, or unusual tire wear indicating improper installation.

More procedures for this vehicle