Replace the front lower control arm bushings on a 2023 Chevrolet Bolt EUV, requiring control arm removal and reinstallation with proper torque sequence.

Warnings

Tools required

Parts

• Front lower control arm bushing kit × 2 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and ensure it is powered off completely
2. Disconnect the 12V battery negative terminal
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise vehicle and support securely on jack stands under frame rails
5. Remove front wheel on the side being serviced
6. Apply penetrating lubricant to ball joint nut, control arm bolts, and sway bar link connections
7. Photograph or mark alignment reference points if available

Procedure

1. 1

   Disconnect sway bar link from control arm
   Locate the sway bar link connection to the lower control arm. Hold the link shaft with an Allen key to prevent spinning, then remove the lower sway bar link nut using an 18mm socket. Separate the link from the control arm and move it aside.
   Torque spec

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

   Remove ball joint cotter pin and nut
   Straighten and remove the cotter pin from the ball joint castle nut. Using a 19mm socket, remove the ball joint nut completely. Do not reuse the cotter pin.
   Torque spec

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

   Separate ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the ball joint stud from the steering knuckle. Apply force gradually to avoid damaging the knuckle or surrounding components. The control arm should now be able to drop away from the knuckle.
   ⚠Do not strike the steering knuckle directly with a hammer as this may damage wheel bearing or ABS sensor components.
4. 4

   Support control arm
   Place a floor jack or support under the outer end of the control arm to support its weight and prevent it from dropping suddenly when the mounting bolts are removed.
5. 5

   Remove control arm mounting bolts
   Locate the front and rear control arm mounting bolts at the subframe. Using a 19mm socket and breaker bar, remove both control arm mounting bolts completely. Note the orientation of any washers or spacers for reinstallation.
   ℹ️These bolts are typically very tight. A breaker bar or impact wrench may be necessary for removal.
   Torque spec

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

   Remove control arm from vehicle
   Lower the jack supporting the control arm and carefully maneuver the control arm out of the vehicle. Work it past the drive axle and any brake lines or ABS wiring as needed. Inspect the ball joint and all mounting points for wear or damage.
7. 7

   Press out old bushings
   Using a hydraulic press and appropriate size receiver cups and drivers, press the old bushings out of the control arm. Press from the side that allows the bushing to move into the larger opening. Clean the bushing bores thoroughly with a wire brush and inspect for cracks or damage.
   ⚠Ensure the control arm is properly supported in the press to prevent it from shifting during bushing removal.
8. 8

   Install new bushings
   Apply a light coating of dish soap or approved bushing lubricant to the new bushings and control arm bores. Using the hydraulic press with correct size driver cups, carefully press the new bushings into the control arm until fully seated and centered. Ensure bushings are oriented correctly per manufacturer specifications.
   ℹ️Do not use petroleum-based lubricants on rubber bushings as they can cause deterioration.
9. 9

   Install control arm to subframe
   Position the control arm back into the vehicle, maneuvering it past the drive axle. Align the control arm with the subframe mounting points. Insert both control arm mounting bolts and thread them by hand, but DO NOT torque them yet. Leave bolts loose enough to allow the control arm to pivot.
   ℹ️Control arm bolts must not be torqued until the vehicle weight is on the suspension to ensure proper bushing alignment.
10. 10

    Connect ball joint to knuckle
    Raise the control arm using a floor jack until the ball joint stud aligns with the hole in the steering knuckle. Insert the ball joint stud through the knuckle and install the castle nut. Torque the ball joint nut to specification and install a new cotter pin through the castle nut and ball joint stud. Bend the cotter pin ends to secure.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Reconnect sway bar link
    Align the sway bar link with the control arm mounting point. Insert the link stud and install the nut. 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
    Reinstall the wheel and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the suspension is at normal ride height with full vehicle weight on the wheels, but keep the jack in place for safety. The suspension must be loaded before torquing control arm bolts.
13. 13

    Torque control arm bolts under load
    With the vehicle weight on the suspension at normal ride height, torque both front and rear control arm mounting bolts to specification. This is critical for proper bushing function and longevity.
    ⚠Failure to torque control arm bolts with vehicle weight on suspension will cause premature bushing failure and handling issues.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final wheel installation
    Raise the vehicle slightly to remove the jack, then lower completely to the ground. Torque all wheel lug nuts to specification in a star pattern.
    Torque spec

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

    Reconnect battery and test
    Reconnect the 12V battery negative terminal. Power on the vehicle and check for any warning lights. Test drive the vehicle at low speed in a safe area to verify proper operation and listen for any unusual noises.

Reassembly

1. Repeat all steps for the opposite side if replacing both control arm bushings
2. Verify all fasteners are torqued to specification, especially control arm bolts which must be torqued under vehicle load
3. Ensure new cotter pin is properly installed and secured on ball joint
4. Check that no tools or parts were left in the wheel well area

Verification

• Test drive vehicle and verify no clunking, rattling, or unusual noises from front suspension
• Verify steering feels normal with proper return to center
• Check that vehicle tracks straight with no pulling to either side
• Schedule a professional wheel alignment as suspension work typically requires alignment adjustment
• After 50-100 miles, re-check torque on all fasteners, particularly wheel lug nuts

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