Upper Control Arm - Rear

Remove and replace the rear upper control arm on a 2005 Dodge Viper, requiring vehicle lifting, suspension disassembly, and precise torque specifications during reassembly.

Warnings

Tools required

Parts

• Rear upper control arm × 1 — Use OEM specification
• Upper ball joint nut (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle with floor jack at manufacturer-approved jacking point
5. Support vehicle securely on jack stands positioned at frame or subframe hard points
6. Remove rear wheel completely
7. Spray all control arm fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle or lower control arm to support the suspension in a neutral position. Raise jack just enough to take light load off the upper control arm but not enough to compress the suspension. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Remove the upper ball joint castle nut
   Remove the fastener securing the upper ball joint (or upper link) to the rear knuckle per the vehicle-specific service manual. If equipped with a castle nut and cotter pin, remove the cotter pin first, then remove the nut using a socket and breaker bar. Verify the attachment type against the FSM before proceeding. Keep the nut if reusing or discard if damaged.
   Torque spec

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

   Separate the ball joint from the knuckle
   Install a ball joint separator tool between the upper control arm and knuckle. Tighten the separator tool to apply pressure to the ball joint taper. Tap the knuckle boss with a hammer while maintaining pressure to break the taper fit and separate the ball joint stud from the knuckle. Do not use excessive force that could damage the knuckle or ball joint bore.
4. 4

   Remove the front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the suspension cradle or chassis bracket. Using a socket and breaker bar, remove the bolt completely. Note the orientation of any washers or spacers for reassembly. The bolt passes through the front bushing of the control arm.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove the rear control arm mounting bolt
   Locate the rear mounting bolt that secures the upper control arm to the suspension cradle or chassis bracket. Using a socket and breaker bar, remove the bolt completely. Note the orientation of any washers or spacers for reassembly. The bolt passes through the rear bushing of the control arm.
   Torque spec

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

   Remove the upper control arm
   With both mounting bolts removed, carefully maneuver the upper control arm out of the suspension area. You may need to adjust the jack supporting the knuckle slightly to create clearance. Remove the control arm from the vehicle and set aside.
7. 7

   Clean mounting points and inspect
   Use a wire brush to clean the mounting bolt holes in the chassis brackets and the ball joint taper bore in the knuckle. Inspect the ball joint taper bore for damage, scoring, or elongation. Inspect chassis mounting points for cracks, excessive rust, or damage. Clean mounting bolt threads; do not apply anti-seize unless specified by the service manual, as it alters torque values and can lead to over-tightening.
8. 8

   Install the new upper control arm
   Position the new upper control arm into place, aligning the front and rear bushings with the chassis mounting brackets. Insert the front mounting bolt through the chassis bracket and control arm bushing but do not tighten. Insert the rear mounting bolt through the chassis bracket and control arm bushing but do not tighten. Leave both bolts finger-tight only at this stage.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Connect the ball joint to the knuckle
   Adjust the floor jack to raise or lower the knuckle until the upper ball joint stud aligns with the hole in the knuckle. Insert the ball joint stud into the knuckle taper bore. Install the castle nut onto the ball joint stud and tighten to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure.
   Torque spec

   Ball Joint Nut88 Nm (65 lb-ft)
10. 10

    Reinstall the wheel
    Mount the rear wheel onto the hub and thread on all lug nuts by hand. Tighten lug nuts in a star pattern to snug but do not torque to final specification yet. Lower the vehicle from jack stands so that the vehicle weight rests on the wheels but keep the floor jack available for final height adjustment.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)
11. 11

    Torque control arm mounting bolts with weight on wheels
    With the vehicle weight fully on the wheels and suspension at normal ride height, torque the front control arm mounting bolt to specification. Then torque the rear control arm mounting bolt to specification. This critical step ensures the control arm bushings are torqued in their natural operating position, preventing premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Final torque wheel lug nuts
    With the vehicle on the ground, torque all wheel lug nuts to specification in a star pattern. Perform final pattern check to ensure even torque distribution.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)

Reassembly

1. Reassembly is covered in the installation steps above
2. Ensure all fasteners are torqued to specification with vehicle weight on wheels as noted
3. Verify cotter pin is properly installed and bent on ball joint castle nut

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the rear suspension
• Check for proper handling and stability during turns
• Perform visual inspection under vehicle to confirm all fasteners are tight and properly installed
• Schedule wheel alignment immediately after this repair, as upper control arm replacement affects rear camber and toe settings

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