Strut Assembly - Rear

This procedure covers the removal and replacement of the rear strut assembly on a 2023 Chevrolet Bolt EUV, including disconnection from the knuckle and strut tower.

Warnings

Tools required

Parts

• Rear strut assembly (complete) × 1 — GM OEM or KYB/Monroe equivalent
• Anti-seize compound × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake.
2. Place wheel chocks in front of front wheels.
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground.
4. Raise rear of vehicle using floor jack at approved rear jacking point.
5. Support vehicle on jack stands placed at designated rear lift points per owner's manual.
6. Remove rear wheel completely.
7. Spray penetrating oil on strut-to-knuckle bolts and strut tower nuts, allow 10-15 minutes to penetrate.
8. Support rear knuckle/suspension with floor jack to prevent sudden drop when strut is disconnected.

Procedure

1. 1

   Access strut tower mounting nuts
   Open rear cargo area. Fold down rear seat if needed for access. Locate and remove the interior trim panel covering the strut tower. On the Bolt EUV, this is typically a small circular or rectangular access cover on the cargo floor near the rear quarter panel. Use trim removal tools to avoid breaking clips.
2. 2

   Remove strut tower mounting nuts
   Locate the three strut tower mounting nuts at the top of the strut assembly. Using a 15mm socket, remove all three nuts. Hold the strut shaft from rotating if necessary (center nut). Do NOT allow the strut to drop at this point; it is still connected to the knuckle below.
   ⚠Support the strut assembly from below with a jack to prevent it from falling once nuts are removed.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
3. 3

   Disconnect sway bar link (if applicable)
   If the sway bar link interferes with strut removal, disconnect it from the strut assembly. Using an 18mm wrench on the nut and a hex key to hold the shaft, remove the upper sway bar link nut. Pivot the link away from the strut.
   Torque spec

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

   Remove strut-to-knuckle bolts
   Locate the two bolts connecting the strut assembly to the rear knuckle. These are large diameter bolts typically requiring an 18mm or 19mm socket. Remove both bolts completely. You may need to use a pry bar to spread the knuckle bracket slightly to release the strut. Note the orientation and any alignment marks.
   ⚠The strut will be free to move once these bolts are removed. Ensure the suspension is supported by a floor jack to control movement.
   Torque spec

   Strut-to-Knuckle Bolts122 Nm (90 lb-ft)
5. 5

   Remove strut assembly
   With all fasteners removed, carefully guide the strut assembly out of the knuckle bracket and down through the suspension area, then up and out through the strut tower opening in the cargo area. The strut may need to be angled or rotated to clear brake lines, electrical connectors, and body panels. Work carefully to avoid damaging components.
6. 6

   Inspect and prepare new strut assembly
   Inspect the new strut assembly to ensure it matches the old unit. If installing a complete strut assembly, it should come pre-assembled with spring and mount. If transferring components from old strut, use a proper spring compressor to safely disassemble and reassemble. Clean the knuckle mounting area and strut tower mating surfaces with a wire brush. Apply light coat of anti-seize to strut-to-knuckle bolt threads (not the clamping area).
   ⚠️Only disassemble strut springs using a proper spring compressor. Incorrect technique can result in catastrophic spring release causing severe injury or death.
7. 7

   Install new strut assembly into vehicle
   Guide the new strut assembly up through the cargo area strut tower opening, then down into position. Align the top mounting studs through the strut tower holes. Insert the lower portion of the strut into the knuckle bracket, aligning bolt holes. You may need to use a jack to raise or lower the knuckle slightly for alignment.
8. 8

   Install strut tower mounting nuts
   Hand-thread all three strut tower mounting nuts onto the upper studs. Do not fully torque at this stage. Snug them down evenly to pull the strut mount flush against the tower, but final torque will be applied later.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
9. 9

   Install strut-to-knuckle bolts
   Insert both strut-to-knuckle bolts through the knuckle bracket and strut. If necessary, use a pry bar or suspension spreader to open the knuckle bracket slightly. Ensure bolts are fully seated. Hand-thread nuts onto bolts but do not torque yet.
   Torque spec

   Strut-to-Knuckle Bolts122 Nm (90 lb-ft)
10. 10

    Reconnect sway bar link
    If disconnected earlier, reconnect the sway bar link to the strut assembly. Insert the link stud through the mounting hole and install the nut. Hold the link shaft with hex key and torque the nut to specification: 55 Nm (41 lb-ft).
    Torque spec

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

    Torque strut tower nuts
    Using a torque wrench and 15mm socket, torque the three strut tower mounting nuts to specification: 50 Nm (37 lb-ft). Torque in a star pattern to ensure even loading.
    ⚠️CRITICAL TORQUE SPECIFICATION. Under-torquing can result in strut separation and loss of vehicle control.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
12. 12

    Torque strut-to-knuckle bolts
    Using a torque wrench and appropriate socket, torque both strut-to-knuckle bolts to specification: 122 Nm (90 lb-ft). Ensure the knuckle bracket is fully seated against the strut before torquing.
    ⚠️CRITICAL TORQUE SPECIFICATION. These bolts control strut-to-knuckle connection and affect suspension geometry and safety.
    Torque spec

    Strut-to-Knuckle Bolts122 Nm (90 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, hand-threading all lug nuts. Lower the vehicle until the wheel just contacts the ground but the suspension is not fully loaded. Torque the wheel lug nuts to specification in a star pattern: 136 Nm (100 lb-ft). Fully lower the vehicle and remove jack stands. Remove wheel chocks.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reinstall the interior trim panel over the strut tower access opening in the cargo area, ensuring all clips are properly seated.
2. Return rear seat to normal position if it was folded.
3. Test drive the vehicle in a safe area at low speed to verify proper strut operation and listen for any unusual noises.
4. After 50-100 miles of driving, re-check torque on all fasteners, especially strut-to-knuckle bolts and strut tower nuts.

Verification

• Verify all fasteners are torqued to specification using a calibrated torque wrench.
• Inspect that no tools or parts were left in the suspension or cargo area.
• Test drive vehicle and verify normal suspension operation with no clunking, rattling, or unusual noises.
• Verify proper vehicle ride height compared to opposite side.
• Check for any fluid leaks from strut seal.
• Schedule a professional wheel alignment immediately after strut replacement, as suspension geometry has been altered.

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