Subframe Bushing

This procedure covers the removal and replacement of the subframe bushings on a 2005 Dodge Viper, requiring the subframe to be lowered for bushing access and replacement.

Warnings

Tools required

Parts

• Subframe bushing set (front and rear) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts on all four wheels while vehicle is on ground
3. Raise vehicle using floor jack at manufacturer-specified lift points
4. Support vehicle securely on jack stands at all four corners, ensuring adequate working height for subframe removal
5. Remove all four wheels
6. Apply penetrating oil to all subframe mounting bolts and allow to soak
7. Photograph or mark steering linkage and suspension component positions for reference during reassembly

Procedure

1. 1

   Disconnect steering linkage
   Locate the steering rack connection points to the subframe. Remove the cotter pins and loosen the castle nuts securing the outer tie rod ends to the steering knuckles. Use a tie rod separator or pickle fork to separate the tie rod ends from the knuckles. Support the steering rack to prevent strain on the steering column connection.
2. 2

   Disconnect front sway bar links
   Locate the front sway bar end links connecting the sway bar to the lower control arms. Hold the shaft with an Allen key and remove the upper nuts securing each end link. Disconnect both end links from the sway bar, allowing the sway bar to hang freely from the subframe.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Disconnect lower control arms from knuckles
   Locate the ball joint connecting each lower control arm to the steering knuckle. Remove the cotter pin and loosen the castle nut on each side. Use a ball joint separator to disconnect the ball joints from the knuckles. The control arms will remain attached to the subframe.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
4. 4

   Support subframe with transmission jack
   Position a transmission jack or subframe support fixture under the center of the subframe. Raise the jack until it makes solid contact with the subframe and is supporting the weight. Ensure the support is stable and centered to prevent the subframe from tilting during removal. Use wood blocks or subframe adapters to distribute load evenly.
   ⚠️The subframe weighs approximately 150-200 pounds with components attached. Ensure support equipment is rated appropriately and positioned securely.
5. 5

   Remove subframe mounting bolts
   Locate all subframe-to-chassis mounting bolts. Locate all subframe-to-chassis mounting points and note the number and location of fasteners as documented in the factory service manual. Starting with the rear bolts, loosen but do not fully remove all mounting bolts. Once all bolts are loose, slowly lower the transmission jack while guiding the subframe. Remove the mounting bolts completely as the subframe is lowered. Lower the subframe approximately 6-8 inches or until the bushings are accessible for removal.
   ⚠Lower the subframe gradually and evenly. Watch for any wiring, brake lines, or hoses that may still be connected or may become pinched.
6. 6

   Inspect and mark bushing orientation
   With the subframe lowered, inspect all bushing mounting locations. Note the orientation of each bushing, including any offset positioning, alignment tabs, or voids in the bushing design. Take photographs or make detailed notes of the installed orientation, as bushings are often directional. Check for any metal sleeves or inserts that must be retained and transferred to new bushings.
7. 7

   Remove old subframe bushings
   Using a bushing press or hydraulic press with appropriate adapters, press out the old bushings from the subframe mounting points. Work carefully to avoid damaging the subframe mounting bores. If bushings are seized, apply heat carefully to the metal mounting boss (not the bushing) to aid removal. Clean all mounting bores thoroughly with a wire brush, removing any rust, debris, or old bushing material. Inspect bores for damage or ovaling.
   ⚠Use proper size adapters to press against the bushing outer shell, not the center sleeve, to avoid damaging the subframe bore.
8. 8

   Install new subframe bushings
   Apply a light coating of soapy water or bushing installation lubricant to the outer diameter of the new bushings and the mounting bores. Do not use petroleum-based lubricants as they can degrade the bushing material. Align each new bushing according to the orientation marks from Step 6, ensuring any voids or offsets match the original position. Using the bushing press with appropriate adapters, press each bushing into its bore until fully seated and flush with the subframe mounting surface. Verify that any metal sleeves are centered and perpendicular to the mounting surface.
9. 9

   Raise and align subframe
   Using the transmission jack, carefully raise the subframe back into position, aligning the bushing centers with the chassis mounting bolt holes. Use alignment pins or guide bolts to help position the subframe correctly. Ensure all brake lines, wiring harnesses, and other components are routed correctly and not pinched. Install all subframe mounting bolts finger-tight initially to allow for final positioning adjustment.
   ⚠Do not force the subframe into position. If bolt holes do not align, lower and reposition the subframe. Forcing alignment can damage new bushings or bend mounting brackets.
10. 10

    Torque subframe mounting bolts
    Once all mounting bolts are installed and the subframe is properly aligned, torque the subframe mounting bolts to the factory-specified value (verify against 2005 Viper service manual) in the manufacturer-recommended sequence. This ensures even loading on the bushings and proper subframe alignment. After initial torque, perform a second pass to verify all bolts are properly torqued. Note: Subframe Mounting Bolts
    Torque spec

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

    Reconnect lower control arm ball joints
    Clean the ball joint tapers on both the control arms and steering knuckles. Align each lower control arm ball joint with its corresponding steering knuckle. Install the castle nuts and torque to the factory-specified value (verify against 2005 Viper service manual). Install new cotter pins through the castle nut slots and ball joint studs, bending the pins to secure.
    Torque spec

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

    Reconnect front sway bar links
    Lift the sway bar and align the end links with the mounting points on the lower control arms. Install the mounting hardware and hold the shaft with an Allen key while torquing the nuts to the factory-specified value (verify against 2005 Viper service manual).
    Torque spec

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

    Reconnect steering linkage
    Align the outer tie rod ends with the steering knuckle tapers. Install the castle nuts and torque according to manufacturer specifications. Install new cotter pins and bend to secure. Verify that the steering rack is properly seated on the subframe mounting points and all connections are secure.
14. 14

    Install wheels and lower vehicle
    Install all four wheels, threading lug nuts by hand initially. Lower the vehicle until the wheels just touch the ground but the suspension is not fully loaded. Torque the wheel lug nuts to the factory-specified value (verify against 2005 Viper service manual, approximately 110 lb-ft) in a star pattern. Fully lower the vehicle and remove jack stands. Perform a final torque check on all lug nuts.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Final settling procedure
    With the vehicle on the ground and at normal ride height, bounce each corner of the vehicle several times to allow the suspension and new bushings to settle into their operating position. After settling, verify that all fasteners installed during this procedure remain tight. Check that no components are binding or contacting where they should not.

Reassembly

1. Ensure all fasteners are torqued to specification before returning vehicle to service
2. Verify steering wheel is centered and steering operates smoothly through full range of motion
3. Check that all suspension components move freely without binding
4. Confirm no tools or parts were left in the work area

Verification

• Start the vehicle and turn the steering wheel lock-to-lock while stationary to verify no binding or unusual noises
• Test drive the vehicle at low speed in a safe area, checking for proper steering response and suspension operation
• Listen for any clunking, rattling, or abnormal noises from the subframe area during driving and over bumps
• Schedule professional wheel alignment immediately, as this procedure will have altered suspension geometry
• After 50-100 miles, re-torque all subframe mounting bolts and suspension fasteners to specification
• Inspect all work areas for any signs of loosening fasteners or component movement after initial drive cycle

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