Replace the front lower control arm radius arm bushings on a 2023 Chevrolet Bolt EUV, requiring removal of the control arm and pressing new bushings into position.

Warnings

Tools required

Parts

• Radius arm bushing kit (front lower control arm) × 2 — Use OEM specification
• Ball joint cotter pin × 2 — Use OEM specification

Preparation

1. Ensure vehicle is on level ground and powered off completely
2. Chock rear wheels securely
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at proper lift points
5. Remove front wheels completely

Procedure

1. 1

   Remove ball joint cotter pin and loosen nut
   Remove the cotter pin from the lower ball joint castle nut using a cotter pin removal tool. Discard the old cotter pin. Loosen the ball joint nut but do not remove it completely yet - leave it threaded on a few turns to protect the threads during separation.
2. 2

   Separate ball joint from knuckle
   Using a ball joint separator tool, break the taper connection between the ball joint stud and steering knuckle. Once the joint releases, remove the ball joint nut completely. Support the knuckle to prevent strain on the CV axle and brake hose.
   ⚠Do not strike the ball joint stud with a hammer as this can damage the threads. Use a proper ball joint separator tool.
3. 3

   Disconnect sway bar link if necessary
   If the sway bar link interferes with control arm removal, disconnect it from the control arm by removing the lower sway bar link nut. Hold the shaft with an Allen key to prevent spinning while loosening the nut.
   Torque spec

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

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt that connects the radius arm to the subframe. This bolt passes through the radius arm bushing. Support the control arm with a jack or stand, then remove this bolt completely. Note the orientation of any washers or spacers.
   ⚠The control arm will pivot freely once this bolt is removed. Ensure it is properly supported.
5. 5

   Remove front control arm mounting bolt
   Remove the front control arm mounting bolt that secures the control arm to the front subframe mount. This may require significant force if the fastener has thread-locking compound. Apply penetrating oil if necessary and use a breaker bar for leverage.
6. 6

   Remove control arm from vehicle
   With both mounting bolts removed and the ball joint disconnected, carefully maneuver the control arm out from the suspension. You may need to rotate or angle the arm to clear the subframe and other components. Inspect the ball joint and control arm for any damage or excessive wear.
7. 7

   Press out old radius arm bushing
   Secure the control arm in a hydraulic press or use a portable ball joint press. Position a properly sized bushing driver or receiver on the old bushing. Press the old bushing out of the control arm, ensuring the arm is adequately supported during pressing. Clean the bushing bore thoroughly with a wire brush, removing all rust and debris.
   ⚠️Wear safety glasses and keep hands clear when operating hydraulic press. Ensure control arm is properly supported and cannot shift during pressing operation.
8. 8

   Press in new radius arm bushing
   Apply a light coat of soapy water or bushing lubricant to the outer shell of the new bushing (do not use petroleum-based lubricants). Position the new bushing in the control arm bore with correct orientation - ensure any voids or flat sections align per manufacturer specifications. Using the hydraulic press and proper bushing driver, press the new bushing into the control arm until it is fully seated and flush with the bore edges.
   ⚠Bushing orientation is critical. Installing the bushing backwards or misaligned will cause premature failure and handling issues.
9. 9

   Reinstall control arm to subframe
   Position the control arm back into the suspension mounting points. Insert the front control arm bolt first, threading it by hand to hold the arm in position. Then insert the rear radius arm bolt through the new bushing. Thread both bolts by hand but do NOT torque them at this time - they must be torqued with vehicle weight on the wheels.
10. 10

    Reconnect ball joint to knuckle
    Align the ball joint stud with the hole in the steering knuckle. Install the ball joint castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, then bend the ends of the cotter pin to secure it properly.
    ⚠Always use a new cotter pin. Never reuse old cotter pins as they may fail.
    Torque spec

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

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the control arm. Hold the shaft with an Allen key while torquing the nut to specification.
    Torque spec

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

    Reinstall wheels and lower vehicle
    Reinstall the front wheels and thread lug nuts by hand. Lower the vehicle until the tires just contact the ground but the suspension is not yet fully loaded. Torque the wheel lug nuts to specification in a star pattern. Then lower the vehicle completely so full vehicle weight is on the wheels.
    Torque spec

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

    Torque control arm bolts with vehicle weight on wheels
    With the vehicle's full weight now on the wheels and suspension at normal ride height, torque both control arm mounting bolts (front and rear) to specification. This ensures the bushings are torqued in their normal operating position, preventing binding and premature wear.
    ⚠This step is critical. Control arm bushings must be torqued at normal ride height or they will twist during suspension movement, causing premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if both radius arm bushings are being replaced
2. Perform a final inspection of all fasteners to ensure proper torque
3. Remove jack stands and lower vehicle completely

Verification

• Test drive vehicle at low speed and verify no clunking or abnormal noises from front suspension
• Check steering response and verify vehicle tracks straight with no pulling
• Perform visual inspection under vehicle to confirm all fasteners are tight and cotter pins are properly installed
• Schedule a professional wheel alignment as suspension geometry has been disturbed

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