This procedure covers the removal and replacement of the front upper control arm bushings on a 2023 Chevrolet Bolt EUV, requiring separation of the ball joint and control arm from the chassis.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and engage 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 lift points
5. Remove front wheel on side being serviced
6. Spray control arm bolts and ball joint nut with penetrating lubricant and allow to soak

Procedure

1. 1

   Remove ball joint cotter pin and nut
   Locate the upper ball joint where it connects to the steering knuckle. Remove the cotter pin using a cotter pin remover or side cutters. Discard the old cotter pin. Using a socket and breaker bar, loosen and remove the ball joint nut. Do not reuse this nut if it shows any deformation.
2. 2

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint stud from the steering knuckle. Position the separator between the control arm and knuckle, then tighten or strike as appropriate for your tool type. Do not use excessive force that could damage the knuckle. Once separated, support the knuckle assembly to prevent strain on brake hose and ABS wiring.
   ⚠A pickle fork will likely damage the ball joint boot. Use only if replacing the entire control arm. For bushing-only replacement, use a proper ball joint separator tool.
3. 3

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that attach the control arm to the frame rail or subframe. These are typically a front and rear bolt passing through the control arm bushings. Mark the orientation of any eccentric washers or alignment shims if present. Using a socket and breaker bar, remove both control arm mounting bolts. Support the control arm as the second bolt is removed.
4. 4

   Remove control arm from vehicle
   Once both mounting bolts are removed and ball joint is separated, maneuver the control arm out of the vehicle. You may need to angle it to clear the subframe and other suspension components. Note any spacers or washers on the mounting bolts and their positions for reassembly.
5. 5

   Press out old bushings
   Using a hydraulic press or control arm bushing service tool set, press the old bushings out of the control arm. Select the appropriate receiver cup that is slightly larger than the bushing outer diameter, and a driver that contacts only the bushing, not the control arm. Apply pressure steadily until the bushing is fully removed. Clean the bushing bore with a wire brush and inspect for cracks or damage.
   ⚠Ensure press adapters are properly aligned to prevent damage to the control arm. The bushing bore must remain circular and undamaged.
6. 6

   Install new bushings
   Apply a light coating of dish soap or bushing installation lubricant (never petroleum-based products) to the new bushing outer diameter and control arm bore. Position the new bushing at the bore opening, ensuring proper orientation if the bushing has a specific direction. Using the press and appropriate adapters, press the new bushing in until it is fully seated and flush with the control arm. The bushing should be centered in the bore. Repeat for the second bushing if the control arm has two.
7. 7

   Install control arm to frame
   Position the control arm back into the mounting location on the subframe. Install both control arm mounting bolts with any spacers or washers in their original positions. Thread the bolts in by hand to ensure proper alignment. Do NOT torque these bolts yet - they must be torqued with vehicle weight on wheels. Snug the bolts hand-tight plus 1/4 turn only.
8. 8

   Reconnect ball joint to knuckle
   Position the ball joint stud through the hole in the steering knuckle. Install the ball joint nut and tighten to specification. Install a new cotter pin through the castle nut and ball joint stud. Bend the cotter pin ends to secure. If the cotter pin holes do not align, tighten the nut further (never loosen) until the next slot aligns with the hole.
   ⚠Always use a new cotter pin. Never reuse old cotter pins as they may be fatigued and fail.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Install wheel and lower vehicle
   Reinstall the wheel and thread lug nuts on by hand. Lower the vehicle until the tire just touches the ground but the suspension is not yet compressed. Torque the lug nuts to specification in a star pattern. Then lower the vehicle completely so full weight is on the wheels.
   Torque spec

   Wheel Lug Nuts136 Nm (100 lb-ft)
10. 10

    Torque control arm bolts with vehicle at ride height
    With the vehicle at normal ride height and full weight on the wheels, crawl under the vehicle and torque both control arm mounting bolts to specification. This is critical - torquing these bolts with the suspension hanging will twist the bushings and cause premature failure. Ensure the torque wrench clicks at the specified value for both bolts.
    ⚠This step is critical and must be performed with vehicle weight on wheels. Failure to do so will result in binding, premature bushing wear, and poor handling.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are properly torqued according to specifications
2. Confirm new cotter pin is properly installed and secured
3. Check that no tools or parts were left in the wheel well
4. Inspect brake lines and ABS wiring for proper routing and security

Verification

• Bounce the front suspension by pressing down on the front bumper - there should be no unusual noises or binding
• Turn the steering wheel lock-to-lock while stationary - listen for any binding or clicking from the upper control arm area
• Test drive vehicle at low speed in a safe area and verify normal steering response and no pulling
• Schedule a professional alignment within 50 miles as suspension geometry has been disturbed
• After 50-100 miles of driving, re-verify torque on control arm bolts

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