Replace the front upper control arm bushings on a 1966 Chevrolet Corvette 327ci V8, requiring removal of the upper control arm and pressing out the old bushings.

Warnings

Tools required

Parts

• Front upper control arm bushing set (2 bushings per arm) × 2 — Use OEM specification
• Upper ball joint castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and secure on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Spray all fasteners with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm, close to the lower ball joint. Raise the jack to compress the coil spring and load the lower control arm. On the 1966 Corvette the coil spring seats on the lower control arm, so the jack must safely capture spring tension and remain in place throughout disassembly. This relieves tension on the upper ball joint and keeps the suspension stable during the procedure.
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint stud where it connects to the steering knuckle. Remove the cotter pin using pliers and discard. Using a socket, remove the castle nut from the upper ball joint stud. Do not fully separate the joint yet.
3. 3

   Separate upper ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper ball joint stud from the steering knuckle. Insert the tool between the control arm and knuckle, then strike with a hammer or apply pressure until the taper breaks free. The knuckle will drop down onto the lower ball joint once separated.
4. 4

   Remove upper control arm shaft bolts
   Locate the 2 bolts securing the upper control arm shaft to the frame crossmember. These bolts pass through the bushings and shaft. Using a socket and wrench, remove both bolts completely. Support the control arm as you remove the second bolt to prevent it from falling.
5. 5

   Remove upper control arm assembly
   Carefully maneuver the upper control arm assembly out from between the frame and knuckle. The arm, shaft, and old bushings come out as a unit. Inspect the arm for cracks, bends, or damage while removed.
6. 6

   Mark bushing orientation
   Before pressing out the old bushings, mark the orientation of the bushings relative to the control arm shaft and frame mounting points using a paint pen or marker. Note any offset or angular positioning of the bushing sleeves. This ensures correct installation of the new bushings.
7. 7

   Press out old bushings from shaft
   Using a hydraulic press or bushing press kit, press the old bushings off the control arm shaft. Position the shaft in the press with the bushing supported on the bottom receiver cup. Apply steady pressure to drive the shaft through the bushing. Remove both bushings from the shaft. Clean the shaft thoroughly with a wire brush.
8. 8

   Install new bushings onto shaft
   Position the first new bushing on the press with the control arm shaft aligned to press through it. Ensure the bushing orientation matches the marks made earlier. Press the shaft through the bushing until the bushing is fully seated in the correct position. Repeat for the second bushing. The bushings should be positioned at the correct spacing to align with the frame mounting brackets.
9. 9

   Reinstall upper control arm assembly
   Maneuver the control arm assembly with new bushings back into position between the frame crossmember and steering knuckle. Align the bushing sleeves with the frame mounting holes. Insert the 2 mounting bolts through the bushings and frame brackets and hand-tighten the nuts.
10. 10

    Connect upper ball joint to knuckle
    Raise the floor jack under the lower control arm to lift the steering knuckle up to the upper ball joint stud. Guide the ball joint stud through the hole in the top of the knuckle. Install the castle nut onto the ball joint stud and tighten to specification.
11. 11

    Tighten upper control arm shaft bolts
    With the suspension at normal ride height (supported by the jack under the lower control arm), tighten the 2 upper control arm shaft bolts to specification. It is critical that these bolts are torqued with the suspension loaded to prevent binding of the bushings during suspension travel.
12. 12

    Install new cotter pin
    Install a new cotter pin through the hole in the ball joint stud and castle nut. If the holes do not align, tighten the nut further until the next slot aligns with the hole. Never loosen the nut to align. Bend the cotter pin ends to secure.
13. 13

    Remove jack and reinstall wheel
    Lower and remove the floor jack from under the lower control arm. Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground and torque the lug nuts to specification in a star pattern.

Reassembly

1. Repeat entire procedure for opposite side if both sides require bushing replacement
2. Control arm shaft bolts must be torqued with suspension at ride height to prevent bushing bind
3. Always use a new cotter pin on the ball joint stud

Verification

• Check that upper control arm moves freely through full suspension travel with no binding
• Verify ball joint castle nut is properly torqued and cotter pin is installed
• Test drive vehicle and verify no clunking or unusual noises from front suspension
• Schedule a front-end alignment as bushing replacement will affect camber and caster settings

More procedures for this vehicle