Complete replacement of both front strut assemblies on a 2023 Chevrolet Bolt EUV, including removal of strut-to-knuckle connections and upper strut tower mounting.

Warnings

Tools required

Parts

• Front strut assembly (complete) × 2 — Use OEM specification or quality aftermarket
• Strut upper mounting nuts (if corroded) × 6 — GM 11588692 or equivalent
• Strut-to-knuckle bolts and nuts × 4 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Disconnect 12V battery negative terminal and wait 2 minutes for airbag system to discharge
5. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified jacking points
6. Remove front wheels completely
7. Spray penetrating oil on strut-to-knuckle bolts, sway bar link nuts, and upper strut tower nuts (allow 10-15 minutes to penetrate)

Procedure

1. 1

   Access upper strut tower mounting
   Open the hood and locate the upper strut tower mounting in the engine bay. On the driver side, you may need to move aside the washer fluid reservoir or other components for access. The upper mount has three nuts (13mm) securing the strut to the strut tower. Do NOT remove these nuts yet.
2. 2

   Disconnect sway bar end link
   Locate the sway bar end link connection at the strut. Using an Allen key to hold the shaft from rotating, remove the upper sway bar link nut (18mm). Separate the link from the strut mounting point. If the ball stud spins, use penetrating oil and hold with locking pliers or replace the link.
   ℹ️If sway bar link is worn or damaged, this is an ideal time to replace it.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
3. 3

   Remove brake line bracket
   Locate the brake line bracket or ABS sensor wire bracket attached to the strut body. Remove the mounting bolt (typically 10mm) and carefully position the brake line aside. Do not allow brake lines to hang unsupported or become kinked.
   ⚠Do not damage brake lines or ABS sensor wiring. Support lines with wire or zip ties if necessary.
4. 4

   Remove strut-to-knuckle bolts
   Locate the two bolts securing the strut to the steering knuckle at the bottom of the strut assembly. These are large bolts (18mm head) with nuts on the backside. Support the knuckle assembly with a jack or jack stand. Use a breaker bar to loosen both bolts, then remove completely. Note the orientation of any eccentric washers or alignment marks for reassembly.
   ⚠The knuckle assembly will become loose once these bolts are removed. Ensure it is adequately supported to prevent damage to CV axle, brake components, or ball joints.
   Torque spec

   Strut-to-Knuckle Bolts122 Nm (90 lb-ft)
5. 5

   Separate strut from knuckle
   With bolts removed, carefully pull the knuckle assembly away from the strut. You may need to use a pry bar to spread the knuckle slot slightly. Work carefully to avoid damaging the knuckle bore. Once separated, support the knuckle/hub assembly with a jack or suspend with wire to prevent stress on the CV axle and ball joint.
   ⚠Do not allow the knuckle to hang freely. This can damage the CV axle joint or outer tie rod end.
6. 6

   Remove upper strut tower nuts
   Return to the engine bay and locate the three upper strut mount nuts (13mm). While supporting the strut assembly from below (it will drop when released), remove all three nuts. Carefully lower the strut assembly down and out through the wheel well.
   ⚠The strut assembly is heavy and awkward. Have an assistant support it from below or use a transmission jack to control the descent.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
7. 7

   Prepare new strut assembly
   If installing complete strut assemblies, inspect new struts to ensure they match the old units. Verify spring orientation, upper mount position, and overall length. If transferring components from old struts, use proper spring compressors following all manufacturer safety instructions. Ensure upper mount is oriented correctly with alignment marks facing forward.
   ⚠️If compressing springs, ensure compressor is properly engaged and rated for the spring load. Compress evenly and never place body parts in line with potential spring release path.
8. 8

   Install new strut to tower
   Lift the new strut assembly up through the wheel well, aligning the upper mount studs with the three holes in the strut tower. Install the three upper nuts hand-tight. Ensure the mount is properly seated and oriented correctly (alignment tab or notch should face forward or match the orientation noted during disassembly).
   ℹ️Do not fully torque upper nuts until strut is connected to knuckle and vehicle weight is on suspension.
9. 9

   Connect strut to knuckle
   Position the knuckle assembly to align with the strut mounting bracket. Insert the two strut-to-knuckle bolts from the front, ensuring proper orientation of any eccentric washers or alignment cams. Install nuts on the backside and hand-tighten. Verify the knuckle is fully seated in the strut bracket before proceeding.
10. 10

    Torque strut-to-knuckle bolts
    Using a calibrated torque wrench, tighten both strut-to-knuckle bolts to specification. Torque the upper bolt first, then the lower bolt. Hold the nut on the backside while torquing the bolt head to prevent damage to threads.
    Torque spec

    Strut-to-Knuckle Bolts122 Nm (90 lb-ft)
11. 11

    Torque upper strut tower nuts
    Return to the engine bay and torque all three upper strut mount nuts to specification in a star pattern (alternate between nuts to ensure even seating). Verify the mount is properly seated against the strut tower.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
12. 12

    Reconnect brake line bracket and sway bar link
    Reinstall the brake line or ABS sensor bracket to the strut body and torque the mounting bolt as appropriate. Connect the sway bar end link to the strut, holding the shaft with an Allen key while torquing the nut to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
13. 13

    Repeat for opposite side
    Perform steps 1 through 12 for the opposite side strut assembly, maintaining the same attention to detail and torque specifications.
14. 14

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, threading lug nuts by hand to prevent cross-threading. Lower vehicle until wheels just contact the ground but vehicle weight is not fully on suspension. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

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

    Reconnect battery and final checks
    Reconnect the 12V battery negative terminal. Start the vehicle and verify no warning lights appear. Turn steering wheel lock-to-lock while stationary to verify full range of motion without binding or noise. Test drive at low speed in a safe area to verify proper operation before normal driving.

Reassembly

1. All torque specifications are CRITICAL and must be followed exactly
2. Verify all brake line and ABS sensor connections are secure and properly routed
3. Ensure no tools or parts were left in the wheel well or engine bay
4. Double-check that all fasteners are fully tightened before test driving

Verification

• Visually inspect all connections for proper installation and torque
• Bounce each corner of the vehicle to verify struts are functioning (should rebound smoothly without excessive bouncing)
• Test drive at low speed and verify no unusual noises, vibrations, or handling issues
• Verify steering returns to center properly and tracks straight on level road
• Schedule wheel alignment within 50 miles of strut replacement to prevent premature tire wear
• Re-torque wheel lug nuts after 50-100 miles of driving

More procedures for this vehicle