This procedure covers the removal and replacement of the front steering knuckle/spindle assembly on a 2023 Chevrolet Bolt EUV, including disconnection from the strut, ball joint, and wheel hub.

Warnings

Tools required

Parts

• Front steering knuckle assembly × 1 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification
• Wheel hub bearing (if not included with knuckle) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal and wait 2 minutes
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
6. Remove front wheel completely

Procedure

1. 1

   Remove brake caliper and rotor
   Remove the two brake caliper mounting bolts and carefully slide caliper off the rotor. Support caliper with wire or bungee cord to avoid stressing the brake hose - do not let it hang freely. Remove the brake rotor from the hub. If rotor is stuck, use two M8 bolts in the threaded holes to press it off.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
2. 2

   Disconnect wheel speed sensor
   Locate the wheel speed sensor connector on the back of the knuckle assembly. Press the release tab and disconnect the electrical connector. Remove the sensor mounting bolt and carefully extract the sensor from the knuckle bore. Set aside in a clean location to prevent contamination.
3. 3

   Remove outer tie rod end
   Remove the castle nut securing the outer tie rod end to the steering knuckle. If the tie rod stud spins, hold it with a wrench on the flats. Use a pickle fork or tie rod separator to break the taper connection between the tie rod and knuckle. Do not strike the knuckle directly with a hammer to avoid damage.
4. 4

   Disconnect sway bar link
   Locate the sway bar link connection at the strut. Hold the ball stud shaft with an Allen key to prevent rotation, then remove the upper sway bar link nut. Once loose, detach the sway bar link from the strut assembly.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
5. 5

   Remove strut-to-knuckle bolts
   Locate the two large bolts securing the bottom of the strut to the steering knuckle. These are critical fasteners that align the strut to the knuckle. Mark the position of the strut relative to the knuckle with a paint pen for reference during reassembly. Remove both strut-to-knuckle bolts completely. Support the knuckle as you remove the second bolt.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
6. 6

   Separate lower ball joint
   Remove the castle nut from the lower ball joint stud at the base of the knuckle. Remove and discard the cotter pin first. Once the nut is removed, use a ball joint separator tool to break the taper connection. Apply upward pressure to the knuckle while using the separator to avoid damaging threads. The knuckle should now be free from the lower control arm.
   ⚠Ball joint may release suddenly when taper breaks. Keep hands clear of pinch points.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
7. 7

   Remove knuckle from axle shaft
   With all connections detached, carefully pull the knuckle assembly outward from the vehicle. The CV axle shaft will slide out of the wheel hub bearing bore in the knuckle. If the hub is tight on the axle, use a hub puller to press the axle out of the bearing. Be careful not to damage the CV axle boots or allow the axle to hang unsupported - support it with wire or rest it on the lower control arm.
   ⚠Do not allow CV axle to hang freely or overextend, as this can damage the inner joint or transmission seal.
8. 8

   Inspect and prepare new knuckle
   Inspect the removed knuckle for damage and verify the failure mode. Clean all mating surfaces on the strut, control arm, and tie rod using a wire brush. Apply rust penetrant to threads if needed. Inspect the new knuckle to ensure the hub bearing is properly installed (if applicable). Apply a thin coat of anti-seize to the CV axle splines and hub bearing bore contact area.
9. 9

   Install knuckle onto axle shaft
   Carefully guide the new knuckle onto the CV axle shaft, aligning the splines with the hub bearing. Push the knuckle fully onto the axle shaft until it seats. Position the knuckle to align with the strut and lower ball joint locations.
10. 10

    Connect lower ball joint
    Align the lower ball joint stud with the hole in the bottom of the knuckle. You may need to use a pry bar to position the control arm properly. Push the stud through until it protrudes from the top. Install the castle nut and torque to specification. Align the castle nut slots with the ball joint stud hole and install a NEW cotter pin. Bend the cotter pin ends to secure.
    Torque spec

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

    Reconnect strut to knuckle
    Align the knuckle mounting flange with the strut using your alignment marks from disassembly. Insert both strut-to-knuckle bolts and hand-tighten. Ensure the bolts are properly seated through both the strut and knuckle. Torque both bolts to specification in a cross pattern.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
12. 12

    Reconnect sway bar link and tie rod
    Attach the sway bar link to the strut. Hold the ball stud with an Allen key and install the nut, torque to specification. Reconnect the outer tie rod end to the steering knuckle, ensuring the taper seats properly. Install and torque the tie rod castle nut to specification (consult service manual for tie rod torque value if performing full service).
    Torque spec

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

    Reinstall wheel speed sensor
    Clean the wheel speed sensor bore in the knuckle if necessary. Insert the wheel speed sensor carefully into the bore until fully seated. Install the mounting bolt and torque to specification. Reconnect the electrical connector until it clicks into place.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Reinstall brake rotor and caliper
    Slide the brake rotor onto the hub. Install the brake caliper over the rotor and align with the mounting bracket. Install both caliper mounting bolts and torque to specification. Ensure the caliper slides freely and brake pads are properly positioned on either side of the rotor.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
15. 15

    Reinstall wheel and lower vehicle
    Install the wheel onto the hub and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground but still allows the wheel to spin freely. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands. Reconnect the 12V battery negative terminal.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. All fasteners must be torqued to specification using a calibrated torque wrench
2. New cotter pin must be used on ball joint - never reuse old cotter pins
3. Verify all electrical connections are fully seated and secured
4. Pump brake pedal several times before moving vehicle to restore brake pressure

Verification

• With vehicle on ground, bounce the front end to settle suspension and verify no unusual noises
• Turn steering wheel lock-to-lock while stationary to check for binding or interference
• Test drive at low speed in a safe area and verify steering response is normal with no pulling or vibration
• Check for any fluid leaks around brake components
• Schedule a professional front-end alignment immediately - this repair will affect camber, caster, and toe settings

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