Upper Control Arm - Rear

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

Warnings

Tools required

Parts

• Rear upper control arm × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification
• Upper ball joint (if worn or damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Place wheel chocks in front of the front wheels.
3. Loosen rear wheel lug nuts while vehicle is on ground, but do not remove.
4. Raise the rear of the vehicle using a floor jack at the rear differential or approved jacking point.
5. Support the vehicle securely on jack stands placed under the frame rails.
6. Remove the rear wheel completely.
7. Spray penetrating oil on all control arm fasteners and ball joint nut if corrosion is present. Allow to soak.

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle or lower control arm to support the suspension weight. Raise the jack just enough to take up the weight but not to lift the vehicle off the jack stands. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Remove the upper ball joint cotter pin
   Locate the upper ball joint castle nut where the upper control arm connects to the rear knuckle. Straighten and remove the cotter pin from the castle nut. Discard the old cotter pin.
3. 3

   Loosen the upper ball joint castle nut
   Using an 18mm wrench or socket, loosen the castle nut on the upper ball joint stud. Do not remove the nut completely yet; leave it threaded on a few turns to prevent the ball joint from separating violently when freed.
4. 4

   Separate the upper ball joint from the knuckle
   Use a ball joint separator or pickle fork to break the taper between the ball joint stud and the knuckle. Position the tool appropriately and strike or apply pressure according to the tool design. Once the taper breaks free, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠When the taper breaks, the arm may drop suddenly. Ensure the floor jack is supporting the knuckle and keep hands clear.
5. 5

   Mark the control arm position
   Before removing the control arm mounting bolts, use a paint pen, marker, or tape to mark the position of the control arm relative to the frame mounting bracket. This provides a reference point for installation and helps minimize alignment changes. Note the position of any adjustment shims or eccentric washers if present.
6. 6

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the frame bracket. Using a 19mm socket and wrench, remove the bolt completely. Support the control arm as you remove the bolt to prevent it from dropping.
   Torque spec

   Control Arm Bolts102 Nm (75 lb-ft)
7. 7

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that secures the upper control arm to the frame bracket. Using a 19mm socket and wrench, remove the bolt completely. The upper control arm can now be removed from the vehicle. Inspect the bushings in the mounting points for wear or damage.
   Torque spec

   Control Arm Bolts102 Nm (75 lb-ft)
8. 8

   Inspect and prepare the new control arm
   Compare the new upper control arm to the removed unit to verify correct fitment. Check that all bushings are properly installed and that the ball joint stud moves freely with appropriate resistance. Clean the mounting areas on the frame bracket with a wire brush to ensure proper seating.
9. 9

   Install the new upper control arm
   Position the new upper control arm into the frame mounting bracket, aligning it with the reference marks made during removal. Insert the front mounting bolt first, then the rear mounting bolt. Thread the bolts hand-tight but do not torque yet. The control arm should be able to pivot slightly on the bolts.
   ℹ️Control arm bolts must be torqued with the vehicle weight on the suspension to avoid preloading the bushings.
10. 10

    Connect the ball joint to the knuckle
    Raise the upper control arm ball joint stud into the tapered hole in the rear knuckle. You may need to use the floor jack under the knuckle to adjust the height for alignment. Install the castle nut onto the ball joint stud and tighten to specification using an 18mm wrench or socket.
    Torque spec

    Ball Joint Nut58 Nm (43 lb-ft)
11. 11

    Install the new cotter pin
    Align the castle nut slots with the hole in the ball joint stud. If the slots do not align, tighten the nut slightly (never loosen) until alignment is achieved. Insert a new cotter pin through the castle nut and stud, then bend the ends of the pin to secure it.
12. 12

    Reinstall the wheel
    Mount the rear wheel onto the hub and hand-thread all lug nuts. Lower the vehicle carefully off the jack stands until the tires just touch the ground but the vehicle weight is still partially supported by the jack. This allows the suspension to settle into its normal ride height position.
13. 13

    Torque the control arm mounting bolts
    With the vehicle weight on the suspension (tires on ground, suspension loaded), torque the front and rear upper control arm mounting bolts to specification using a 19mm socket and torque wrench. This ensures the bushings are not preloaded in a twisted position.
    ⚠Torquing control arm bolts with the suspension hanging will cause premature bushing failure.
    Torque spec

    Control Arm Bolts102 Nm (75 lb-ft)
14. 14

    Torque the wheel lug nuts
    Lower the vehicle completely to the ground and remove the jack. Using a torque wrench, tighten the wheel lug nuts to specification in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Reassembly is covered in the installation steps above.
2. Ensure all fasteners are torqued to specification.
3. Verify the new cotter pin is properly installed and secured.

Verification

• Visually inspect all fasteners to confirm they are tight and properly installed.
• Check that the cotter pin is properly bent and secured through the ball joint castle nut.
• Bounce the rear of the vehicle gently to settle the suspension and verify no unusual noises.
• Test drive the vehicle at low speed in a safe area and listen for any clunking or unusual sounds from the rear suspension.
• Schedule a four-wheel alignment as soon as possible, as the upper control arm position affects camber and toe settings.

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