Sway Bar - Front

This procedure covers the removal and replacement of the front sway bar (stabilizer bar) on a 2023 Chevrolet Bolt EUV, including disconnecting the sway bar links and removing the mounting brackets.

Warnings

Tools required

Parts

• Front sway bar × 1 — Use OEM specification
• Sway bar bushings × 2 — Use OEM specification
• Sway bar bracket bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at manufacturer-specified jacking points
5. Secure vehicle on jack stands at designated support points
6. Remove both front wheels completely
7. Spray penetrating oil on sway bar link nuts and bracket bolts if corrosion is present, allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect left sway bar link
   Locate the sway bar link connecting the sway bar to the left strut assembly. Using an Allen key to hold the shaft from rotating, remove the upper nut securing the sway bar link to the strut. Note the orientation of any washers or spacers for reinstallation.
   Torque spec

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

   Disconnect right sway bar link
   Repeat the process on the right side. Hold the sway bar link shaft with an Allen key and remove the upper nut. The sway bar should now be free from both struts but still mounted to the subframe via the bushings and brackets.
   Torque spec

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

   Remove left sway bar bracket
   Locate the sway bar mounting bracket on the left side of the subframe. Remove the two bolts securing the bracket to the subframe. Note the bracket orientation for reinstallation. The bracket and bushing will come off together.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
4. 4

   Remove right sway bar bracket
   Remove the two bolts securing the right sway bar bracket to the subframe. Support the sway bar as you remove the final bolts, as it will now be free from the vehicle.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
5. 5

   Remove sway bar from vehicle
   Carefully maneuver the sway bar out from under the vehicle, noting its orientation and routing path. The bar will need to be angled and rotated to clear the subframe and other components. Take note of how it sits for reinstallation.
   ⚠The sway bar weighs approximately 15-20 lbs and has extended arms that can catch on components during removal.
6. 6

   Inspect and prepare components
   Inspect the sway bar link connections at the struts for wear or damage. Clean the mounting surfaces on the subframe where the brackets attach using a wire brush. Remove old bushing material if bushings are being replaced. Check bracket bolt threads and replace if damaged or corroded.
7. 7

   Install new bushings on sway bar
   If replacing bushings, slide the new sway bar bushings onto the bar in the correct orientation. The bushing split should face toward the rear of the vehicle when installed. Ensure bushings are centered on the bar where the brackets will mount.
8. 8

   Install sway bar into vehicle
   Carefully maneuver the sway bar (with new bushings installed) back into position under the vehicle, reversing the removal path. Align the bushings with the mounting locations on the subframe. Ensure the sway bar ends are positioned near their respective link attachment points on the struts.
9. 9

   Install sway bar brackets
   Place the mounting brackets over the bushings on both sides. Start all four bracket bolts by hand to ensure proper thread engagement. Verify bushings are properly seated and centered before tightening. Torque all bracket bolts in a cross pattern on each bracket.
   Torque spec

   Sway Bar Bracket Bolts47 Nm (35 lb-ft)
10. 10

    Reconnect sway bar links
    Align the sway bar link upper studs with the mounting points on both struts. Install washers (if applicable) and nuts onto the upper link studs. Hold the link shaft with an Allen key to prevent rotation while torquing the nuts to specification on both sides.
    Torque spec

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

    Reinstall wheels
    Install both front wheels and hand-tighten all lug nuts. Lower the vehicle to the ground so the wheel weight is fully supported. Torque the lug nuts to specification in a star pattern to ensure even seating.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Ensure all bracket bolts and link nuts are torqued to specification
2. Verify sway bar has proper clearance from all surrounding components and does not contact exhaust, brake lines, or wiring
3. Check that bushings are not twisted or misaligned in their brackets

Verification

• Bounce the front of the vehicle to ensure sway bar operates smoothly without binding or unusual noises
• Visually inspect all connections to confirm proper installation and torque
• Test drive the vehicle at low speed in a safe area, making gentle turns to verify proper operation
• Listen for any clunking or rattling noises from the front suspension that would indicate loose or improperly installed components
• Re-check wheel lug nut torque after 50-100 miles of driving

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