Control Arm Bushing - Front Lower

This procedure covers the removal and replacement of the front lower control arm bushings on a 2005 Dodge Viper, requiring removal of the control arm from the vehicle for bushing service.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (left) × 1 — Use OEM specification or Moog K200869
• Front lower control arm bushing kit (right) × 1 — Use OEM specification or Moog K200869
• Cotter pins × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands under frame rails
4. Remove front wheels
5. Spray penetrating oil on control arm bolts, ball joint nut, and sway bar link hardware if corrosion is present
6. Allow 15-20 minutes for penetrating oil to work if applied

Procedure

1. 1

   Disconnect sway bar link from control arm
   Locate the sway bar link connection to the front lower control arm. Hold the link shaft with an Allen key to prevent rotation, then remove the lower nut securing the link to the control arm. The link can remain attached to the sway bar.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove ball joint cotter pin and loosen nut
   Locate the ball joint stud where the lower control arm connects to the steering knuckle. If a cotter pin is fitted, remove it using a cotter pin puller or needle-nose pliers (verify retention type against the service manual, as some applications use a self-locking nut). Loosen the ball joint nut but do not remove it completely yet - leave it threaded on a few turns to protect the threads during separation.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
3. 3

   Separate ball joint from knuckle
   Position a ball joint separator or pickle fork between the control arm and the steering knuckle at the ball joint taper. Strike the separator with a hammer to break the taper joint free. Once the taper is broken, remove the ball joint nut completely and lower the control arm away from the knuckle. Support the knuckle with wire or a bungee cord to prevent strain on the brake hose and ABS sensor wiring.
   ⚠Keep the separator tool away from CV boots, brake lines, and ABS wiring. Taper joint will break free suddenly.
4. 4

   Mark control arm position
   Before removing the control arm mounting bolts, mark the position of the control arm relative to the frame or crossmember using a paint marker or scribe. This will help with initial alignment during reinstallation. Note the orientation of any washers or alignment shims if present.
   ℹ️Some vehicles have alignment shims or cam bolts. Verify if your vehicle has these before removal.
5. 5

   Remove front control arm mounting bolt
   Support the control arm with a floor jack or by hand. Remove the front control arm mounting bolt that secures the arm to the front crossmember or frame. This bolt passes through the front bushing. The bolt head is typically accessed from the front.
   ⚠Control arm will drop when bolts are removed. Ensure it is supported and will not fall on hands or feet.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove rear control arm mounting bolt
   Remove the rear control arm mounting bolt that secures the arm to the rear crossmember or frame mount. This bolt passes through the rear bushing. With both bolts removed, carefully lower and remove the control arm from the vehicle.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Inspect control arm and bushings
   With the control arm removed, inspect it for cracks, bends, or damage. Examine the existing bushings for wear, cracking, or separation from the metal sleeve. Clean the bushing bores in the control arm using a wire brush to remove rust and debris.
   ℹ️If control arm is bent or damaged, replace the entire arm rather than just the bushings.
8. 8

   Press out old bushings
   Using a hydraulic press and appropriately sized adapters from a bushing press kit, press the old bushings out of the control arm. Position the control arm so the bushing can be pressed through without obstruction. Apply steady pressure until the bushing is fully removed. Repeat for both front and rear bushings. Note the orientation of the bushings before removal - some bushings have a void or flat area that must align with suspension movement.
   ⚠Ensure press adapters fully support the control arm and do not contact the ball joint or other components. Use appropriate eye protection.
9. 9

   Prepare and press in new bushings
   Clean the bushing bores thoroughly with a wire brush and solvent. Apply a light coat of dish soap or bushing lubricant to the outer sleeve of the new bushings - do not use petroleum-based grease. Position the new bushing in the bore with the correct orientation (voids or flats should align with the suspension's direction of travel, typically fore-aft). Using the hydraulic press and adapters, press the new bushing into the control arm until it is fully seated and flush. The bushing should be centered in the bore. Repeat for the second bushing.
   ⚠Bushing orientation is critical for proper suspension function and bushing life. Verify alignment before pressing.
10. 10

    Reinstall control arm to frame
    Position the control arm into its mounting location on the frame or crossmember, aligning it with the marks made during removal. Insert the front mounting bolt through the bushing and frame, threading it in by hand. Insert the rear mounting bolt through the bushing and frame, threading it in by hand. Do not torque these bolts yet - leave them snug enough to hold the arm in place but loose enough to allow bushing rotation when the suspension is loaded.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Reconnect ball joint to knuckle
    Raise the control arm using a floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and thread on the ball joint nut. Torque the nut to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
    ℹ️If cotter pin hole does not align after torquing to specification, tighten further to the next alignment point. Never loosen to align.
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
12. 12

    Reconnect sway bar link
    Position the sway bar link stud through the mounting hole in the control arm. Thread on the nut while holding the link shaft with an Allen key. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Reinstall wheel and lower vehicle
    Reinstall the wheel and thread on the lug nuts by hand. Torque lug nuts to specification in a star pattern. Repeat procedure for opposite side if replacing both sides. Lower the vehicle until the tires just contact the ground but most of the vehicle weight is still on the jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Torque control arm bolts at ride height
    With the vehicle at normal ride height (tires on ground, suspension loaded), torque both control arm mounting bolts to specification. This ensures the bushings are not pre-twisted and will have maximum service life. Lower vehicle completely from jack stands after torquing.
    ⚠Torquing control arm bolts while suspended will pre-load bushings and cause premature failure. Always torque at ride height.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Reassembly is covered in the procedure steps above
2. Ensure all fasteners are torqued to specification at the correct time (control arm bolts at ride height)
3. Install new cotter pins - never reuse old cotter pins
4. Verify sway bar link is secured with Allen key held during tightening

Verification

• Start engine and turn steering wheel lock-to-lock to verify no binding or interference
• Test drive vehicle at low speed and verify no clunking, popping, or unusual noises from front suspension
• Verify steering returns to center normally
• Check that control arm bolts remain tight after test drive
• Schedule front end alignment within 100 miles - bushing replacement will affect toe and camber settings

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