This procedure covers the removal and replacement of leaf spring bushings on the 2023 Chevrolet Bolt EUV. Note: The Bolt EUV uses a torsion beam rear suspension, not leaf springs, so this procedure addresses the rear torsion beam bushings.

Warnings

Tools required

Parts

• Rear torsion beam bushing kit × 2 — Use OEM specification
• Mounting hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Ensure vehicle is on level ground and parking brake is engaged
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
5. Remove both rear wheels
6. Spray penetrating oil on all rear torsion beam mounting bolts and allow to soak

Procedure

1. 1

   Support the rear torsion beam
   Position a floor jack under the center of the rear torsion beam with a block of wood to protect the beam. Raise jack just enough to support the weight of the beam without lifting the vehicle. This prevents the beam from dropping when mounting bolts are removed.
2. 2

   Disconnect rear sway bar links
   Locate the rear sway bar links connecting the sway bar to the torsion beam. Hold the shaft with an Allen key and remove the nuts from both sides. Set links aside. This provides clearance for torsion beam removal.
   Torque spec

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

   Remove shock absorber lower bolts
   Locate the lower shock absorber mounting bolts at each side where they attach to the torsion beam. Remove these bolts and allow the shock absorbers to hang freely. Support them with wire or bungee cords if necessary to prevent stress on brake lines.
4. 4

   Disconnect brake line brackets
   Identify any brake line mounting brackets attached to the torsion beam. Remove the mounting bolts to free the brake lines from the beam. Be careful not to bend or damage the brake lines. The lines should have enough slack to allow beam lowering.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Remove torsion beam mounting bolts
   Locate the front torsion beam mounting bolts on both sides where the beam mounts to the chassis through the bushings. These are typically large bolts passing through the bushing assembly. Remove these bolts completely while supporting the beam with the jack. Mark the orientation of any washers or spacers for reinstallation.
6. 6

   Lower and remove torsion beam
   Carefully lower the floor jack to bring the torsion beam assembly down and away from the chassis mounting points. You may need to maneuver the beam slightly to clear the mounting points. Once clear, remove the beam from under the vehicle and place on a stable work surface.
7. 7

   Remove old bushings from beam
   Inspect the bushing mounting areas on the torsion beam. Using a hydraulic press or bushing removal tool, press out the old bushings from the beam mounting sleeves. Apply steady pressure and ensure the tool is properly aligned to avoid damage to the mounting sleeve. Clean the bushing bore thoroughly with a wire brush and inspect for damage or cracks.
   ⚠Ensure the pressing tool is properly centered to avoid damaging the mounting sleeve. A damaged sleeve may require torsion beam replacement.
8. 8

   Install new bushings
   Apply a light coat of soapy water or rubber lubricant to the outer surface of the new bushings (do not use petroleum-based lubricants). Position the new bushing at the bore entrance, ensuring proper orientation if the bushing has directional markings. Using the hydraulic press or installation tool, press the bushing squarely into the mounting sleeve until it is fully seated and flush with the beam mounting surface. Repeat for the second bushing.
   ⚠Verify bushing orientation before pressing. Some bushings have offset voids that must align correctly for proper suspension geometry.
9. 9

   Reinstall torsion beam to chassis
   With the jack supporting the torsion beam, maneuver it back into position under the vehicle. Align the new bushings with the chassis mounting points. You may need to use a pry bar to align the mounting holes. Insert the mounting bolts through the bushings and chassis brackets but do NOT fully tighten at this time. Thread bolts in just enough to hold the beam in position.
10. 10

    Reconnect shock absorbers and brake lines
    Reattach the lower shock absorber bolts to the torsion beam mounting points on both sides. Reinstall the brake line mounting brackets to the beam. Ensure all components are properly positioned and hardware is installed.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
11. 11

    Reconnect sway bar links
    Reattach the sway bar links to the torsion beam. Hold the shaft with an Allen key and install the nuts. Torque to specification.
    Torque spec

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

    Torque torsion beam bushings under load
    Remove jack stands and lower the vehicle so that the full weight is on the suspension (tires on ground). This is critical for proper bushing alignment. If control arm torque specifications apply to this mounting, torque the torsion beam mounting bolts to 165 Nm (122 lb-ft). If different bolts are used, consult service manual for proper specification. This must be done with vehicle weight on wheels to prevent bushing bind.
    ⚠Torsion beam bushings must be torqued with vehicle weight on suspension. Torquing while suspended will preload the bushings and cause premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Reinstall wheels and final torque
    Install both rear wheels and hand-tighten lug nuts in a star pattern. Lower vehicle completely to the ground. Torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all brake line brackets are securely fastened and lines are not kinked or stretched
2. Verify all suspension components are properly reconnected and torqued
3. Double-check that torsion beam mounting bolts were torqued with vehicle weight on suspension

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the rear suspension
• Check for proper rear wheel alignment - vehicle should track straight with no pulling
• Inspect all mounting points for proper bolt torque and no looseness
• Listen for any clunking or binding noises when going over bumps, which could indicate improper bushing installation
• After 50-100 miles, re-torque torsion beam mounting bolts to specification

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