Replace worn subframe bushings on the 2023 Chevrolet Bolt EUV to restore ride quality and proper suspension alignment.

Warnings

Tools required

Parts

• Subframe bushing set (front and rear) × 1 — Use OEM specification
• Ball joint cotter pin × 2 — Use OEM specification
• Thread locker (medium strength) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on both front wheels while vehicle is on ground
4. Raise vehicle and support securely on jack stands at manufacturer-approved lift points
5. Remove both front wheels
6. Spray all suspension fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Disconnect sway bar links
   Remove the sway bar link nuts from both sides. Hold the shaft with an Allen key to prevent spinning while removing the upper nuts. This will allow the sway bar to drop away from the control arms.
   Torque spec

   Sway Bar Link61 Nm (45 lb-ft)
2. 2

   Separate ball joints from knuckles
   Remove the cotter pins from both ball joint nuts. Remove the ball joint nuts using a deep socket. Use a ball joint separator tool to separate the ball joints from the steering knuckles. Do not hammer on suspension components.
   ⚠Discard old cotter pins and use new ones during reassembly.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Support the subframe
   Position a transmission jack or suitable subframe support stand under the center of the front subframe. Raise the jack until it just contacts the subframe with minimal pressure. This will support the subframe when mounting bolts are removed.
   ⚠️Ensure support is secure and centered before proceeding. Subframe will drop when bolts are removed.
4. 4

   Remove subframe mounting bolts
   Locate all four subframe mounting bolts (two front, two rear). Using a breaker bar, loosen each bolt but do not fully remove yet. Once all are loose, carefully lower the transmission jack while removing the bolts. Lower the subframe approximately 4-6 inches to access the bushings while ensuring no hoses, wiring, or components are strained.
   ⚠Check that no brake lines, wiring harnesses, or other components are under tension as subframe lowers.
   Torque spec

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

   Remove old bushings
   With the subframe lowered, access is available to the bushing mounting points. Mark the orientation of each bushing before removal. Use a bushing press tool or hydraulic press to remove the old bushings from their mounting locations in the subframe. Clean all bushing bores thoroughly with a wire brush and inspect for damage or cracking.
   ℹ️Front and rear bushings may have different orientations. Note the position of any voids or alignment marks.
6. 6

   Install new bushings
   Apply a light coating of soapy water or bushing lubricant to the new bushings and bores (do not use petroleum-based lubricants). Using the bushing press tool, carefully press new bushings into the subframe mounting locations, ensuring proper orientation matches the original configuration. Bushings should seat fully and evenly in their bores.
   ⚠Incorrect bushing orientation will cause premature wear and handling issues.
7. 7

   Raise and align subframe
   Using the transmission jack, carefully raise the subframe back into position, aligning all mounting bolt holes with the chassis. Guide the subframe into place ensuring no wiring or hoses are pinched. Insert all four mounting bolts finger-tight before torquing any of them.
   ⚠Verify all mounting holes align properly before forcing bolts. Misalignment indicates bushing installation issue.
8. 8

   Torque subframe mounting bolts
   Torque all four subframe mounting bolts to specification in a cross pattern (front left, rear right, front right, rear left) to ensure even seating. Verify the subframe is properly seated against the chassis.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Reconnect ball joints
   Clean the ball joint tapers and knuckle bores. Install the ball joints into the steering knuckles and install new nuts. Torque the ball joint nuts to specification. Install new cotter pins through the castellated nuts and bend the ends to secure.
   ⚠If cotter pin hole does not align, tighten nut slightly more (never loosen to align).
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Reconnect sway bar links
    Attach the sway bar links to the control arms. Hold the shaft with an Allen key and install the nuts. Torque the sway bar link nuts to specification while holding the shaft to prevent spinning.
    Torque spec

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

    Install wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but suspension is not fully loaded. Torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
12. 12

    Final torque with vehicle loaded
    Fully lower the vehicle so that the suspension is at normal ride height with vehicle weight on the wheels. If control arm bolts were loosened during the procedure, torque them now to specification with the suspension loaded. This is critical for proper bushing function and longevity.
    ⚠Control arm bolts must be torqued with vehicle weight on suspension to prevent bushing wind-up and premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Remove jack stands and lower vehicle completely
2. Test drive vehicle at low speed in a safe area to verify no unusual noises or handling issues
3. Schedule a professional wheel alignment as suspension geometry has been altered

Verification

• Verify all mounting bolts are torqued to specification
• Check that all cotter pins are properly installed and bent
• Inspect for any interference between subframe and chassis components
• Test drive and verify improved ride quality and elimination of clunking noises
• Confirm no unusual tire wear after alignment is completed

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