Knuckle/Spindle - Rear

Remove and replace the rear knuckle/spindle assembly on a 2023 Chevrolet Bolt EUV, including disconnection of brake components, suspension links, and hub assembly.

Warnings

Tools required

Parts

• Rear knuckle/spindle assembly × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• Wheel hub bearing (if not included with knuckle) × 1 — Verify if included with knuckle assembly

Preparation

1. Engage parking brake and chock front wheels
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise rear of vehicle and support securely on jack stands at manufacturer recommended lift points
4. Remove rear wheel completely
5. Apply penetrating oil to all fasteners to be removed and allow to soak
6. Place floor jack under lower control arm to support suspension load

Procedure

1. 1

   Remove brake caliper and bracket
   Remove the two brake caliper mounting bolts and slide caliper off rotor. Hang caliper from suspension spring with wire or caliper hanger to prevent strain on brake hose. Then remove the caliper bracket mounting bolts and remove bracket from knuckle.
2. 2

   Remove brake rotor
   If rotor is stuck, use two mounting bolt holes to install bolts that will press rotor off hub. Remove rotor completely to access hub mounting bolts on back of knuckle.
3. 3

   Disconnect sway bar link
   Locate sway bar link connection to knuckle or lower control arm. Hold the link shaft with appropriate Allen key to prevent rotation, then remove the nut. Separate link from mounting point.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
4. 4

   Disconnect lower control arm ball joint
   Remove cotter pin from ball joint castle nut. Remove the castle nut completely. Use ball joint separator tool to break taper connection between ball joint stud and knuckle. Avoid hitting knuckle directly to prevent damage.
   ⚠Do not damage ball joint boot during separation. Support knuckle as tension is released.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
5. 5

   Remove strut-to-knuckle bolts
   Support knuckle assembly with one hand or use additional support. Remove the two bolts connecting the strut to the knuckle. Note the position and orientation of any alignment marks or eccentric washers if present.
   ⚠Knuckle will become free once these bolts are removed. Ensure proper support to prevent dropping.
   Torque spec

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

   Remove wheel hub from knuckle
   With knuckle removed from vehicle, place on clean work surface. Remove the hub mounting bolts from the back side of the knuckle. Separate hub from knuckle, pressing out if necessary. If hub bearing remains in knuckle, use appropriate press or bearing removal tool to extract it.
7. 7

   Clean and inspect mounting surfaces
   Thoroughly clean all mounting surfaces on strut, control arm, and sway bar link connections using wire brush. Remove rust, corrosion, and old thread locker. Inspect all mating surfaces for damage. Apply light coat of anti-seize to bolt threads (except critical torque-to-yield fasteners).
8. 8

   Install hub bearing into new knuckle
   If hub bearing is separate from knuckle assembly, press new bearing into knuckle bore ensuring it is fully seated and square. Install hub into knuckle from front side and secure with mounting bolts from rear. Tighten mounting bolts in star pattern.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Install knuckle to strut
   Position new knuckle assembly to strut and align bolt holes. Insert strut-to-knuckle bolts and hand tighten. Ensure any alignment cams or eccentric washers are in their original positions. Do not fully torque at this time.
10. 10

    Connect lower control arm ball joint
    Guide ball joint stud into knuckle taper. Install castle nut and tighten to specification. Align castle nut slots with stud hole and install new cotter pin. Bend cotter pin ends to secure.
    Torque spec

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

    Reconnect sway bar link
    Position sway bar link to mounting point on knuckle or control arm. Install nut while holding link shaft with Allen key to prevent rotation. Torque to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
12. 12

    Torque strut-to-knuckle bolts
    With suspension components connected, torque the two strut-to-knuckle bolts to specification using torque wrench. Tighten evenly.
    Torque spec

    Strut Bolts115 Nm (85 lb-ft)
13. 13

    Reinstall brake components
    Install brake caliper bracket to knuckle and torque bolts to specification. Place rotor onto hub. Install brake caliper over rotor and torque caliper mounting bolts to specification. Pump brake pedal to restore pad position before moving vehicle.
14. 14

    Install wheel and initial torque
    Mount wheel onto hub and install lug nuts. Hand tighten all lug nuts in star pattern. Lower vehicle until tire just contacts ground but suspension is not fully loaded. Torque lug nuts in star pattern to specification.
    Torque spec

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

    Final torque control arm with vehicle weight
    Lower vehicle completely to ground so full weight is on suspension. If control arm through-bolts were loosened or removed during this procedure, torque them to specification now with vehicle at normal ride height to properly preload bushings.
    ℹ️This step is critical for control arm bushing longevity. Torquing without weight on wheels will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners have been properly torqued using torque wrench
2. Ensure new cotter pin is properly installed and secured on ball joint
3. Verify brake caliper is properly secured and brake hose has no kinks or stress
4. Check that wheel rotates freely without binding or unusual noise

Verification

• Test brake pedal feel - should be firm with no excessive travel before vehicle movement
• Perform test drive at low speed and verify no unusual noises from rear suspension
• Verify straight-line tracking and normal steering feel
• Schedule four-wheel alignment as soon as possible after this repair to ensure proper camber, toe, and caster settings
• Re-torque wheel lug nuts after 50-100 miles of driving

More procedures for this vehicle