Upper Control Arm - Front

This procedure covers the removal and installation of the front upper control arm on a 1992 Dodge Viper, including disconnection from the ball joint and frame mounting points.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Ball joint castle nut cotter pin × 1 — Use OEM specification
• Upper control arm bushings (if separate) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid 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 point
5. Support vehicle securely on jack stands placed at frame rails
6. Remove front wheel completely
7. Spray penetrating lubricant on upper control arm fasteners and ball joint nut; allow to penetrate while gathering tools

Procedure

1. 1

   Remove ball joint cotter pin and castle nut
   Locate the upper ball joint castle nut where the upper control arm connects to the steering knuckle. Straighten and remove the cotter pin using pliers or side cutters. Using the correct socket for the ball joint castle nut (verify size against the service manual), remove the castle nut completely. Do not discard the nut if the ball joint is being reused with the new control arm.
2. 2

   Separate ball joint from knuckle
   Position a ball joint separator or pickle fork between the upper control arm and the steering knuckle at the ball joint taper. Strike the tool firmly with a hammer to break the taper fit, or use a screw-type separator per tool instructions. Once the taper breaks free, the upper control arm will drop away from the knuckle. Support the knuckle and brake assembly to prevent strain on the brake hoses.
   ⚠Using a pickle fork will likely damage the ball joint boot. Use only if replacing the control arm assembly with ball joint included.
3. 3

   Support the lower control arm
   Place a floor jack under the lower control arm near the coil-over/spring seat to support the loaded suspension and prevent it from dropping when the upper control arm is removed. Raise the jack just enough to take up slack without lifting the vehicle off the jack stands.
4. 4

   Remove front control arm mounting bolt
   Locate the front pivot bolt securing the upper control arm to the frame crossmember. This bolt passes through the front bushing of the control arm. Using a wrench to hold the nut and a socket on the bolt head (verify fastener size against the service manual), remove the bolt completely. Note the orientation of any washers or spacers for reinstallation.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear pivot bolt securing the upper control arm to the frame crossmember. This bolt passes through the rear bushing of the control arm. Using a wrench to hold the nut and a socket on the bolt head (verify fastener size against the service manual), remove the bolt completely. The control arm is now free to be removed.
6. 6

   Remove upper control arm from vehicle
   Carefully maneuver the upper control arm out of the suspension area, rotating and angling as necessary to clear the knuckle, frame, and any brake lines. Inspect the removed control arm for bushing wear, ball joint condition, and any signs of impact damage or bending.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting points where the control arm bushings contact the crossmember. Remove rust, dirt, and old thread-locking compound from the bolt holes and mounting surfaces. Inspect the frame mounting ears for cracks or damage.
8. 8

   Install new upper control arm
   Position the new upper control arm into the mounting location on the frame crossmember. Align the front and rear bushing holes with the frame mounting holes. Insert both front and rear pivot bolts with any original washers or spacers in their correct positions. Thread the nuts onto the bolts hand-tight only at this stage. Do not torque yet.
9. 9

   Connect ball joint to knuckle
   Raise the jack under the lower control arm to bring 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 and tighten to the manufacturer-specified torque using the correct socket (verify size against the service manual). Align the castle nut slots with the ball joint stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
   Torque spec

   Ball Joint Nut58 Nm (43 lb-ft)
10. 10

    Lower vehicle to load suspension
    Remove the jack stands and carefully lower the vehicle until the full weight is on the wheels and the suspension is at normal ride height. The wheels should be in contact with the ground but the vehicle can remain supported by the floor jack for stability. This step is critical to prevent bushing bind.
    ⚠Control arm pivot bolts must be torqued with suspension loaded to avoid binding the bushings, which causes premature wear and poor handling.
11. 11

    Torque control arm mounting bolts
    With the vehicle weight on the suspension, torque both the front and rear upper control arm pivot bolts to specification. Use the correct socket on the bolt head and a wrench to prevent the nut from rotating (verify fastener size against the service manual). Torque both pivot bolts to the manufacturer-specified value.
    Torque spec

    Control Arm Bolts102 Nm (75 lb-ft)
12. 12

    Install wheel and lower vehicle
    Reinstall the front wheel, threading the lug nuts by hand to avoid cross-threading. Lower the vehicle completely to the ground. Torque the wheel lug nuts to specification in a star pattern using a torque wrench and the correct socket (verify size against the service manual).
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reassembly is covered in the main procedure steps
2. Ensure all fasteners are torqued to specification with suspension loaded
3. Verify new cotter pin is properly installed and bent at ball joint

Verification

• Visually inspect that all fasteners are installed and properly torqued
• Check that the ball joint cotter pin is installed and the ends are bent to prevent backing out
• Verify no interference between control arm and brake lines, ABS wiring, or other components through full suspension travel
• Test drive the vehicle at low speed and verify normal steering feel and no unusual noises from the front suspension
• Schedule a professional alignment as upper control arm replacement affects camber and caster settings

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