Upper Control Arm - Front

This procedure covers removal and installation of the front upper control arm on a 2005 Dodge Viper, including ball joint separation and proper torque sequence.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Ball joint castle nut (if damaged) × 1 — Use OEM specification
• Cotter pin × 1 — Standard castle nut cotter pin

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle and support on jack stands at manufacturer-specified jacking points
4. Remove front wheel completely
5. Spray penetrating oil on ball joint nut and control arm mounting bolts; allow 10-15 minutes to soak

Procedure

1. 1

   Remove ball joint cotter pin
   Locate the upper ball joint castle nut at the top of the steering knuckle. Use pliers or a cotter pin puller to straighten and remove the cotter pin securing the castle nut. Discard the old cotter pin as it should not be reused.
2. 2

   Remove ball joint castle nut
   Using the correct socket for the ball joint stud nut (verify size against factory service data for this vehicle), remove the castle nut from the upper ball joint stud. Leave the nut threaded on 2-3 turns initially to protect the threads during separation.
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool (pickle fork or puller-style), position the tool between the upper control arm and the steering knuckle. Strike the tool sharply or apply hydraulic pressure (depending on tool type) to separate the ball joint taper from the knuckle. Once the joint breaks free, remove the castle nut completely and lower the knuckle away from the control arm.
   ⚠Wear safety glasses. The separator can slip or the joint can release suddenly.
4. 4

   Mark control arm position
   Before removing the control arm mounting bolts, use a paint marker or scribe to mark the position of the control arm relative to the frame mounting brackets. Note any eccentric washers or cam positions, as these affect alignment. Take a photo if possible for reference during installation.
5. 5

   Support control arm
   Position a floor jack or support under the outer end of the control arm to prevent it from dropping when the mounting bolts are removed. This also relieves tension on the mounting hardware.
6. 6

   Remove control arm mounting bolts
   Locate the two mounting bolts securing the upper control arm to the frame. Using the correct socket (verify size against factory service data) and breaker bar, remove both bolts completely. The control arm has a front bolt and a rear bolt with bushings at each location.
7. 7

   Remove upper control arm
   Lower the floor jack supporting the control arm and guide the arm out of the frame mounting brackets. Maneuver the arm out through the wheel well, being careful not to damage brake lines or ABS sensors. Inspect the removed arm for worn bushings, bent arms, or damaged ball joint boots.
8. 8

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting bracket surfaces and bolt threads. Remove any corrosion, dirt, or old thread locking compound. Ensure bolt threads are clean and dry; do not apply anti-seize to suspension fasteners unless specified by the factory service manual, as it affects torque-to-clamp-load values.
9. 9

   Install new upper control arm
   Position the new or replacement upper control arm into the frame mounting brackets, aligning it with the marks made during removal. Insert both mounting bolts and thread them by hand. Do not torque at this time. Support the outer end of the control arm with a floor jack.
10. 10

    Connect ball joint to knuckle
    Raise the floor jack supporting the control arm to align the ball joint stud with the hole in the top of the steering knuckle. Insert the stud through the knuckle and thread the castle nut onto the stud by hand. Tighten the castle nut using the correct socket (verify size against factory service data).
    Torque spec

    Ball Joint Nut88 Nm (65 lb-ft)
11. 11

    Install 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 further (never loosen) until alignment is achieved. Insert a new cotter pin through the stud hole and bend the ends to secure.
12. 12

    Reinstall wheel and lower vehicle
    Install the front wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground but the suspension is not fully loaded. Tighten lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Torque control arm bolts with weight on wheels
    With the vehicle lowered completely and full weight on the wheels, torque the upper control arm mounting bolts to specification. This ensures the bushings are in their neutral position and prevents binding. Use the correct socket (verify size against factory service data) and torque wrench to torque both the front and rear mounting bolts.
    ⚠This step is critical. Torquing control arm bolts with suspension hanging will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Reverse the removal procedure, ensuring all fasteners are torqued to specification
2. Control arm mounting bolts must be torqued with vehicle weight on wheels
3. Always use a new cotter pin for the ball joint castle nut
4. Verify ball joint castle nut is torqued and cotter pin is properly secured

Verification

• Verify ball joint castle nut is torqued to 65 lb-ft and secured with a new cotter pin
• Verify control arm mounting bolts are torqued to 122 lb-ft with vehicle weight on wheels
• Verify wheel lug nuts are torqued to 100 lb-ft in a star pattern
• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Schedule a front-end alignment immediately after completing this repair, as control arm replacement affects camber and caster settings

Related trouble codes on this vehicle

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