This procedure covers the removal and replacement of the front lower control arm on a 2023 Chevrolet Bolt EUV electric vehicle, including ball joint separation and proper torque sequence at ride height.

Warnings

Tools required

Parts

• Front lower control arm assembly × 1 — OEM or equivalent control arm with ball joint
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Disconnect 12V battery negative terminal
4. Loosen front wheel lug nuts while vehicle is on ground
5. Raise vehicle with floor jack at designated jacking point
6. Support vehicle securely on jack stands at frame rails
7. Remove front wheel completely

Procedure

1. 1

   Remove ball joint cotter pin and nut
   Locate the ball joint stud at the steering knuckle. Remove the cotter pin using pliers or cotter pin removal tool. Discard the old cotter pin. Using an 18mm socket, loosen but do not fully remove the ball joint castle nut. Leave it threaded on a few turns to protect threads during separation.
2. 2

   Separate ball joint from knuckle
   Position ball joint separator tool between the lower control arm and steering knuckle. Apply force to break the taper fit. Once separated, remove the castle nut completely and lower the control arm away from the knuckle. If using a pickle fork, be aware this may damage the ball joint boot on the old control arm.
   ⚠Support the knuckle assembly to prevent stress on brake hose and ABS sensor wiring once ball joint is disconnected.
3. 3

   Disconnect sway bar link (if interfering)
   If access is limited, disconnect the sway bar link from the lower control arm. Use an Allen key to hold the stud and remove the nut with appropriate socket. Note orientation for reassembly.
   Torque spec

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

   Support control arm
   Position a floor jack or jack stand under the outer edge of the control arm to support its weight during bolt removal. This prevents the arm from dropping suddenly and makes installation easier.
5. 5

   Remove rear control arm pivot bolt
   Locate the rear pivot bolt that attaches the control arm to the subframe. This is typically the larger diameter bolt toward the rear of the vehicle. Using a breaker bar and appropriate socket, remove the rear pivot bolt completely. Note the position of any washers or spacers.
   ℹ️Rear bolt may be difficult to remove due to bushing preload. Apply penetrating oil if necessary and allow to soak.
6. 6

   Remove front control arm pivot bolt
   Remove the front pivot bolt that attaches the control arm to the subframe. This bolt is typically located closer to the front of the vehicle. Remove bolt completely and carefully lower the control arm from the vehicle. Note orientation and any alignment marks.
7. 7

   Inspect mounting points and clean
   Inspect the control arm mounting bushings in the subframe for damage, cracks, or excessive wear. Use a wire brush to clean the mounting bolt holes and surfaces. Remove any rust, debris, or corrosion from the ball joint taper seat in the steering knuckle.
8. 8

   Install new control arm
   Position the new control arm into the subframe mounting points. Apply a light coat of anti-seize to bolt threads. Insert both front and rear pivot bolts and thread them by hand. Do NOT torque these bolts yet - they must be torqued at ride height. Leave bolts finger-tight plus 1-2 turns.
9. 9

   Connect ball joint to knuckle
   Raise the outer end of the control arm and align the ball joint stud with the hole in the steering knuckle. You may need to use a pry bar or jack to align the holes. Insert the ball joint stud fully into the knuckle and thread the castle nut onto the stud.
   ℹ️Ensure ball joint stud is fully seated in the taper before tightening nut. Stud should not spin when tightening.
   Torque spec

   Ball Joint Nut100 Nm (74 lb-ft)
10. 10

    Torque ball joint nut and install cotter pin
    Torque the ball joint castle nut to specification. If the cotter pin holes do not align, tighten the nut further (never loosen) until the next castle slot aligns with the hole in the stud. Insert a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut100 Nm (74 lb-ft)
11. 11

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the control arm or strut mounting point. Hold the stud with an Allen key and torque the nut to specification.
    Torque spec

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

    Reinstall wheel and lower vehicle to ride height
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the full weight is on the suspension (ride height) but keep jack in position for safety. This is critical for properly torquing the control arm pivot bolts.
    ⚠Vehicle must be at ride height with weight on suspension before torquing control arm pivot bolts. This ensures proper bushing alignment and prevents premature failure.
13. 13

    Torque control arm pivot bolts at ride height
    With the vehicle at ride height (wheels supporting vehicle weight), torque the front and rear control arm pivot bolts to the specified torque. Access may require reaching under the vehicle or using extensions. Ensure full torque is achieved on both bolts.
    Torque spec

    Lower Control Arm Pivot Bolts175 Nm (129 lb-ft)
14. 14

    Final wheel installation
    Raise vehicle slightly, remove jack stands, and lower vehicle completely to ground. Torque wheel lug nuts to specification in a star pattern to ensure even seating.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reconnect 12V battery negative terminal
2. Test steering through full range of motion to ensure no binding or interference
3. Check that all fasteners are properly torqued and cotter pin is installed
4. Repeat procedure on opposite side if replacing both control arms

Verification

• Verify ball joint cotter pin is properly installed and bent
• Confirm all bolts are torqued to specification, especially control arm pivot bolts which were torqued at ride height
• Test drive vehicle at low speed and verify no abnormal noises, vibrations, or steering issues
• Perform wheel alignment check - control arm replacement typically requires alignment adjustment
• Visually inspect for any interference between control arm and surrounding components through full suspension travel

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