This procedure covers the removal and replacement of the rear leaf spring assembly on a 2023 Chevrolet Bolt EUV, though this vehicle uses a coil spring rear suspension, not leaf springs.

Warnings

Tools required

Parts

• Rear coil spring assembly × 1 — Use OEM specification
• Spring isolator (upper) × 1 — Use OEM specification
• Spring isolator (lower) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake.
2. Place wheel chocks in front of front wheels.
3. Turn off vehicle and remove key fob from interior.
4. Open hood and disconnect negative terminal of 12V battery, then positive terminal.
5. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground.
6. Raise rear of vehicle using floor jack at manufacturer-designated lift points.
7. Support vehicle securely on jack stands placed under frame rails.
8. Remove rear wheels completely and set aside.
9. Spray penetrating oil on all suspension fasteners and allow to soak for 10-15 minutes.

Procedure

1. 1

   Support rear suspension
   Position a floor jack with a block of wood on top under the rear lower control arm or rear knuckle assembly to support the weight of the suspension. Raise jack just enough to compress the suspension slightly and relieve tension on the shock absorber. This prevents the suspension from dropping when components are disconnected.
2. 2

   Disconnect sway bar link
   Locate the rear sway bar link connection at the lower control arm or suspension knuckle. Using a 15mm wrench to hold the shaft and an appropriate socket, remove the sway bar link nut. Disconnect the sway bar link from the suspension to allow full travel range for spring removal.
   Torque spec

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

   Remove shock absorber lower mounting bolt
   Locate the lower shock absorber mounting bolt that connects the shock to the rear knuckle or lower control arm. Using an 18mm socket and ratchet, remove the lower shock mounting bolt completely. Support the shock absorber to prevent it from hanging by the upper mount. This allows the suspension to drop for spring access.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
4. 4

   Carefully lower suspension to access spring
   Very slowly and carefully lower the floor jack supporting the rear suspension. Monitor the spring as the suspension extends. Lower until the coil spring is fully extended and no longer under compression between the upper and lower spring seats. The spring should be loose enough to remove by hand. If spring remains under tension, stop and reassess - do not force.
5. 5

   Remove coil spring and isolators
   Once suspension is fully lowered and spring is unloaded, remove the rear coil spring from between the upper and lower spring seats. Note the orientation and position of the spring end locations. Remove the upper and lower spring isolators (rubber pads) from the spring seats. Inspect spring seats for damage, rust, or debris and clean with wire brush if needed.
6. 6

   Inspect components and prepare new spring
   Inspect the upper and lower spring seats for cracks, excessive rust, or damage. Check shock absorber for leaks or damage. Inspect control arm bushings for wear or tears. Compare new spring with old spring to verify correct part. Install new upper and lower spring isolators onto the new coil spring in the same orientation as removed from the old spring.
7. 7

   Install new coil spring
   Position the new coil spring with isolators into the lower spring seat, ensuring the end of the spring coil is properly located in the seat recess. Align the top of the spring with the upper spring seat location. Ensure the spring is not twisted or misaligned. The spring end positions must match the original configuration.
8. 8

   Raise suspension to compress spring
   Using the floor jack under the lower control arm or knuckle, very slowly raise the suspension. As you raise, guide the top of the coil spring into the upper spring seat, ensuring proper alignment. Continue raising until the spring is fully seated in both upper and lower seats and the suspension is at normal ride height position. Verify spring ends are properly located in their seat recesses.
9. 9

   Reinstall shock absorber lower bolt
   With suspension raised to normal height, align the shock absorber lower mounting eye with the mounting point on the knuckle or control arm. Insert the lower shock mounting bolt and hand-thread the nut. Torque the lower shock bolt to specification using a torque wrench.
   Torque spec

   Strut Bolts115 Nm (85 lb-ft)
10. 10

    Reconnect sway bar link
    Align the sway bar link with its mounting point on the lower control arm or suspension. Install the sway bar link nut and hand-thread. Use an Allen key to hold the shaft while torquing the nut to specification.
    Torque spec

    Sway Bar Link61 Nm (45 lb-ft)
11. 11

    Install wheel and lower vehicle
    Mount the rear wheel onto the hub, ensuring the wheel is seated properly on the hub face. Hand-thread all lug nuts to prevent cross-threading. Snug lug nuts in a star pattern but do not fully torque yet. Carefully lower vehicle from jack stands until tires just touch the ground but vehicle weight is still on stands.
12. 12

    Torque wheel lug nuts
    With vehicle weight beginning to settle on wheels, torque the wheel lug nuts to specification in a star pattern using a torque wrench. Complete at least two full passes in the star pattern to ensure even seating and proper torque.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Final lowering and battery reconnection
    Remove jack stands and carefully lower vehicle completely to the ground. Remove wheel chocks. Reconnect the 12V battery, connecting positive terminal first, then negative terminal. Close hood. Bounce each corner of the vehicle several times to settle the suspension into its normal operating position.

Reassembly

1. Repeat procedure for opposite side if replacing both springs.
2. Ensure all fasteners are torqued to specification.
3. Verify spring isolators are properly seated and not pinched.
4. All suspension fasteners must be torqued with vehicle weight on wheels at normal ride height.

Verification

• Bounce each rear corner of the vehicle and verify smooth, controlled spring action with no unusual noises.
• Verify vehicle sits level side-to-side with no sagging on the replaced spring side.
• Test drive vehicle at low speed and verify normal handling with no clunking, rattling, or abnormal sounds from rear suspension.
• After 50-100 miles of driving, re-check torque on all suspension fasteners.
• Have vehicle alignment checked at a qualified shop, as suspension work may have affected rear alignment settings.

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