Replacement of the front upper control arm on a 1966 Chevrolet Corvette C2, including ball joint separation, shaft removal, and installation of new control arm assembly.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or quality aftermarket equivalent
• Upper ball joint (if not included with control arm) × 1 — Use OEM specification
• Control arm shaft nuts × 2 — 7/8 inch castellated nuts
• Cotter pins × 2 — 1/8 inch diameter

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle using floor jack at factory lift point on frame
5. Support vehicle on jack stands placed under frame rails behind front suspension
6. Remove front wheel completely
7. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Mark alignment position
   Using a paint pen or chalk, mark the current position of the upper control arm shaft and shim pack relative to the frame bracket. This provides a baseline for initial reinstallation to minimize alignment changes. Note the number and location of shims at both the front and rear mounting positions.
2. 2

   Support the spindle assembly
   Place a floor jack with a block of wood under the lower control arm, positioned near the ball joint. Raise the jack just enough to take up the weight of the spindle and brake assembly. This prevents the assembly from dropping when the upper ball joint is separated and protects the brake hose from damage.
3. 3

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint stud where it passes through the top of the spindle. Remove and discard the cotter pin from the castellated nut. Using a 9/16 inch socket or wrench, remove the castle nut from the ball joint stud. Note: Some applications use a 5/8 inch nut.
4. 4

   Separate upper ball joint from spindle
   Using a ball joint separator tool (pickle fork style or tie rod puller), position the tool between the upper control arm and the top of the spindle. Strike the tool firmly with a hammer or tighten the puller screw to force the taper loose. The ball joint stud will pop free from the spindle with a sharp release. Keep hands clear during separation.
   ⚠The separation may occur suddenly. Ensure the spindle is supported by the jack underneath.
5. 5

   Access control arm shaft mounting nuts
   The upper control arm shafts extend through the frame and are secured with nuts on the inboard side. Access these nuts from underneath the vehicle or through the engine compartment. On some 1966 Corvettes, partial removal of the inner fender panel or working from below the frame provides access. Locate the two 7/8 inch nuts securing the control arm shaft bolts.
6. 6

   Remove front control arm shaft nut
   Using a 7/8 inch wrench or socket, hold the bolt head from the outboard side while loosening the inboard nut with a second wrench. Remove the nut completely. Note the position and quantity of any shims between the frame and control arm. These shims control caster and camber angles. Keep shims organized for reinstallation.
7. 7

   Remove rear control arm shaft nut
   Repeat the same procedure for the rear control arm shaft mounting. Remove the 7/8 inch nut while holding the bolt head. Again, carefully note and preserve all alignment shims, keeping the front and rear shim packs separate. The shims at each position set caster and camber.
8. 8

   Remove control arm shaft bolts and control arm
   With both nuts removed, drive the front and rear shaft bolts out through the frame using a brass drift punch and hammer. The bolts pass through the frame bracket and the control arm bushings. Once both bolts are removed, lower the upper control arm away from the frame. Inspect the frame mounting area for damage, rust, or elongated holes.
9. 9

   Prepare new control arm
   Inspect the new upper control arm assembly. Verify that bushings are properly installed and that the ball joint is tight (if pre-installed). Clean the control arm shaft mounting area in the frame using a wire brush to remove rust and debris. Apply a light coating of anti-seize compound to the shaft bolt threads.
10. 10

    Install new upper control arm
    Position the new upper control arm into the frame bracket. Align the bushings with the mounting holes. Install the front and rear shaft bolts from the outboard side, passing them through the frame and control arm bushings. Reinstall the front and rear shim packs in their original positions and quantities as marked in Step 1.
11. 11

    Install shaft mounting nuts loosely
    Thread the 7/8 inch nuts onto both front and rear shaft bolts from the inboard side. Tighten by hand only at this stage. The final torque will be applied after the suspension is loaded to operating height to prevent bushing bind.
12. 12

    Connect ball joint to spindle
    Raise the spindle assembly using the floor jack positioned under the lower control arm. Guide the upper ball joint stud into the tapered hole in the top of the spindle. Thread the castle nut onto the ball joint stud and tighten to specification (typically 50-55 ft-lb for C2 Corvette upper ball joints). Align the castellations with the cotter pin hole and install a new cotter pin, bending the legs to secure.
13. 13

    Load suspension and torque shaft nuts
    With the spindle connected, raise the floor jack under the lower control arm until the suspension is at normal ride height (the vehicle just begins to lift slightly off the jack stands). With the suspension loaded, torque the upper control arm shaft nuts to specification (typically 45-55 ft-lb for 1966 Corvette). This prevents preloading the control arm bushings in a twisted position.
14. 14

    Final inspection
    Remove the floor jack from under the lower control arm. Verify that all fasteners are tight and that new cotter pins are properly installed and bent. Check that the ball joint boot is properly seated and not torn. Verify no interference between the control arm and any brake or suspension components through full steering travel.

Reassembly

1. Reinstall wheel and hand-tighten lug nuts
2. Lower vehicle to ground and remove jack stands
3. Torque wheel lug nuts to specification in a star pattern
4. Bounce front suspension several times to settle components

Verification

• Test drive vehicle at low speed and verify no clunking, popping, or abnormal noises from front suspension
• Check for proper steering return to center
• Inspect upper ball joint dust boot for damage or displacement
• Schedule professional wheel alignment within 50 miles of completion - suspension geometry has been altered and tire wear will result without proper alignment

More procedures for this vehicle