Replace the upper ball joint on a 1966 Chevrolet Corvette, requiring removal of the upper control arm and press-out/press-in of the ball joint.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM specification or K6136 equivalent
• Upper control arm shaft nuts (if damaged) × 2 — Use OEM specification
• Castle nut for ball joint stud × 1 — Use OEM specification
• Cotter pin × 1 — 1/8" x 1.5"

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen lug nuts on the wheel where ball joint is being replaced (do not remove)
4. Raise front of vehicle with floor jack at frame rail
5. Support vehicle securely on jack stands under frame rails
6. Remove wheel and tire assembly
7. Spray penetrating oil on upper control arm shaft nuts and ball joint castle nut

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the spring seat to support the suspension load. Raise jack just enough to make contact but not lift the vehicle. This prevents the suspension from dropping when the upper ball joint is separated.
2. 2

   Remove brake caliper
   Remove the bolts securing the 4-piston brake caliper to the steering knuckle bracket (verify bolt count and socket size against factory manual). Lift caliper off rotor and support it with wire or a bungee cord to the frame. Do not let caliper hang by the brake hose.
3. 3

   Remove castle nut from upper ball joint
   Remove the cotter pin from the upper ball joint castle nut using pliers or side cutters. Using a 5/8" socket, remove the castle nut from the ball joint stud. Do not discard the nut yet as it may be needed for pressing operations.
4. 4

   Separate ball joint from steering knuckle
   Using a ball joint separator (pickle fork or tie rod puller), break the taper fit between the upper ball joint stud and the steering knuckle. Position the separator between the upper control arm and steering knuckle, then strike with a hammer or tighten the forcing screw until the joint separates. The knuckle will drop slightly when freed.
5. 5

   Mark alignment reference
   Using a scribe or marker, mark the position of the upper control arm cross-shaft relative to the frame mounting bracket. On the C2 Corvette, camber and caster shims are located between the cross-shaft and the frame bracket. This provides a reference point for approximate alignment when reinstalling, though a professional alignment will still be required.
6. 6

   Remove upper control arm shaft nuts
   Working from inside the engine compartment, remove the 2 nuts securing the upper control arm shafts to the frame using a 9/16" socket and wrench. The shafts pass through the frame brackets with shims that set camber. Note the position and thickness of any shims for reinstallation.
7. 7

   Remove upper control arm
   Pull the upper control arm forward and down to remove it from the frame mounting brackets. The control arm shafts will slide out of the frame. Keep all shims together and note which shaft they came from.
8. 8

   Press out old ball joint
   Secure the upper control arm in a vise or position it on a ball joint press. Using a ball joint press or C-frame press with the appropriate adapters, press the old ball joint out of the control arm. Position the receiving cup on the bottom side of the control arm and press downward on the ball joint body. The joint is a press fit and will require significant force.
9. 9

   Clean ball joint bore
   Using a wire brush, thoroughly clean the ball joint bore in the upper control arm, removing all rust, dirt, and old debris. Inspect the bore for cracks or damage. The bore must be clean for proper press fit of the new joint.
10. 10

    Press in new ball joint
    Position the new upper ball joint in the control arm bore with the stud pointing downward. Using the ball joint press with appropriate adapters, press the new joint into the control arm until it is fully seated. The joint should press in evenly and seat firmly against the control arm. Do not use the castle nut to draw the joint into place.
11. 11

    Install upper control arm to frame
    Position the upper control arm shafts into the frame mounting brackets, ensuring shims are reinstalled in their original positions. Start both shaft nuts by hand. Align the shafts with the reference marks made during disassembly. Tighten the 2 upper control arm shaft nuts to the value specified in the 1966 Corvette factory service manual (verify exact spec) using a torque wrench.
12. 12

    Connect ball joint to steering knuckle
    Raise the steering knuckle using the floor jack under the lower control arm until the ball joint stud passes through the hole in the knuckle. Install the castle nut on the ball joint stud and tighten to the value specified in the 1966 Corvette factory service manual (verify exact spec), then advance to the next slot to align the cotter pin hole, using a torque wrench and 5/8" socket.
13. 13

    Install cotter pin
    Align the slots in the castle nut with the hole in the ball joint stud. If alignment is not perfect, tighten the nut slightly (never loosen) until the next slot aligns. Install a new cotter pin through the stud hole and bend the ends to secure.
14. 14

    Reinstall brake caliper
    Position the brake caliper over the rotor and align the mounting holes. Install the caliper mounting bolts and tighten to the value specified in the 1966 Corvette factory service manual (verify exact spec and bolt count for the 4-piston disc caliper) using a torque wrench.
15. 15

    Remove jack and reinstall wheel
    Lower and remove the floor jack from under the lower control arm. Install the wheel and tire assembly. Hand-tighten all lug nuts in a star pattern, then torque to the value specified in the 1966 Corvette factory service manual (verify exact spec, typically for 7/16"-20 studs) using a torque wrench.

Reassembly

1. Raise vehicle and remove jack stands, then lower to ground
2. Perform final torque check on wheel lug nuts with vehicle on ground
3. Test drive at low speed to verify no suspension noise or abnormal handling
4. Schedule a professional wheel alignment immediately, as camber and caster settings will be affected

Verification

• Visually inspect that ball joint castle nut has cotter pin properly installed and bent
• Grasp tire at top and bottom and attempt to rock in and out; there should be no play
• Verify brake caliper is secure and brake pedal is firm before test drive
• Check that all fasteners are tight and no tools or parts were left in wheel well
• After test drive, recheck upper control arm shaft nuts for tightness

More procedures for this vehicle