Control Arm Bushing - Front Upper

Replace the upper control arm bushings on the front suspension of a 2005 Dodge Viper, requiring control arm removal and bushing press-out/press-in operations.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (left) × 1 — Use OEM specification
• Front upper control arm bushing kit (right) × 1 — Use OEM specification
• Cotter pin for ball joint × 2 — 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 with floor jack at designated front lift point
5. Support vehicle securely on jack stands under frame rails
6. Remove front wheels completely
7. Spray all suspension fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint where the upper control arm connects to the steering knuckle. Remove the upper ball joint retaining nut. Verify the retention type against the Viper service manual (castle nut with cotter pin vs. prevailing-torque nut), and remove/discard the cotter pin only if equipped. Using a socket and breaker bar, loosen and remove the ball joint nut completely. Do not allow the ball joint stud to spin while removing the nut.
2. 2

   Separate upper ball joint from knuckle
   Position a ball joint separator tool between the upper control arm and steering knuckle, applying pressure to the ball joint taper. Strike the tool or tighten the screw-type separator until the ball joint stud releases from the knuckle taper. Once separated, support the knuckle and brake assembly to prevent strain on the brake hose and ABS sensor wiring.
3. 3

   Remove upper control arm mounting bolts
   Locate the bolts securing the upper control arm pivot to the frame/mount. Verify the exact number and arrangement against the Viper service manual, as the upper arm may pivot on a cross-shaft rather than simple through-bolts. Using a socket and breaker bar, remove both front and rear mounting bolts completely. Note the orientation of any washers or alignment shims for reinstallation. Support the control arm as the second bolt is removed to prevent it from falling.
4. 4

   Remove upper control arm from vehicle
   With both mounting bolts removed and the ball joint separated, carefully maneuver the upper control arm out of the vehicle. You may need to rotate or angle the arm to clear the shock tower and other suspension components. Inspect the control arm for cracks, bends, or other damage while it is removed.
5. 5

   Press out old bushings from control arm
   Secure the control arm in a hydraulic press or bushing press fixture. Position the appropriate bushing removal tool and press adapter to support the outer edge of the control arm while pressing the old bushing out from the opposite side. Apply steady pressure to press the front bushing out completely. Repeat the process for the rear bushing. Clean the bushing bores thoroughly with a wire brush, removing all rust, debris, and old rubber residue.
6. 6

   Press in new bushings
   Apply a light coating of rubber-safe bushing installation lubricant (do not use petroleum-based grease) to the outer sleeve of the new bushings and the control arm bores. Position the new front bushing in the control arm bore, ensuring correct orientation per the bushing manufacturer's markings. Using the hydraulic press with the appropriate installation adapter, press the bushing in until it is fully seated and flush with the control arm. The bushing should press in squarely without cocking to one side. Repeat for the rear bushing. Verify both bushings are fully seated and properly oriented.
7. 7

   Install control arm to frame
   Position the control arm back into the vehicle, aligning the bushing bores with the mounting points on the frame or shock tower. Insert the front and rear mounting bolts through the bushings, installing any washers or alignment shims in their original positions and orientation. Thread the bolts in by hand but do NOT torque them at this time. The bolts must remain loose until the vehicle weight is on the wheels.
8. 8

   Connect upper ball joint to knuckle
   Lift the upper control arm and align the ball joint stud with the tapered hole in the top of the steering knuckle. Insert the stud fully into the taper. Install the ball joint retaining nut onto the stud and tighten to specification per the Viper service manual. If the joint uses a castle nut with a cotter pin, align the castellations with the stud hole (tighten further, never loosen) and install a new cotter pin, bending the legs to secure. If a prevailing-torque nut is used, torque to spec and do not install a cotter pin.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
9. 9

   Install wheels and lower vehicle
   Install the front wheels onto the hubs, threading lug nuts by hand to start. Tighten lug nuts in a star pattern until snug but not fully torqued. Carefully raise the vehicle slightly with the floor jack and remove the jack stands. Lower the vehicle completely so that the full weight is resting on the wheels. Rock the vehicle side-to-side to settle the suspension at normal ride height.
10. 10

    Torque control arm bolts at ride height
    With the vehicle weight fully on the wheels and suspension settled at normal ride height, torque the upper control arm front and rear mounting bolts to specification in sequence. This is critical: torquing the control arm bushings while the suspension is hanging will cause premature bushing failure and binding. Ensure the torque wrench clicks at the specified value for both bolts.
    Torque spec

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

    Final torque wheel lug nuts
    With the vehicle on the ground, torque all wheel lug nuts to specification in a star pattern. Make two complete passes with the torque wrench to ensure even clamping force and proper seating of the wheel.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if both upper control arm bushings are being replaced
2. Verify all fasteners are torqued to specification before driving
3. The control arm mounting bolts MUST be torqued at normal ride height with vehicle weight on wheels

Verification

• Visually inspect that new cotter pins are installed and properly bent on both ball joints
• Verify all mounting bolts are tight and torqued to specification
• Bounce the front suspension several times and verify no abnormal noises or looseness
• Test drive vehicle at low speed and verify smooth suspension operation with no clunking or binding
• Schedule a front-end alignment within 50 miles, as control arm removal will affect alignment settings

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