Front Suspension Rebuild

Complete disassembly, inspection, and rebuild of front suspension including upper and lower control arms, ball joints, bushings, strut assemblies, and sway bar components for the 2008 Dodge Viper.

Warnings

Tools required

Parts

• Upper control arm bushings (left) × 1 — Mopar 68040135AA or equivalent
• Upper control arm bushings (right) × 1 — Mopar 68040135AA or equivalent
• Lower control arm bushings (left) × 1 — Mopar 68040136AA or equivalent
• Lower control arm bushings (right) × 1 — Mopar 68040136AA or equivalent
• Upper ball joint (left) × 1 — Use OEM specification
• Upper ball joint (right) × 1 — Use OEM specification
• Lower ball joint (left) × 1 — Use OEM specification
• Lower ball joint (right) × 1 — Use OEM specification
• Sway bar end links (pair) × 2 — Mopar 68040137AA or equivalent
• Sway bar bushings × 2 — Use OEM specification
• Strut mount bearings (pair) × 2 — Use OEM specification
• Strut dust boots (pair) × 2 — Use OEM specification
• Strut bump stops (pair) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and chock rear wheels securely
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support on jack stands at manufacturer-specified jacking points behind front wheels on chassis rails
4. Remove both front wheels completely
5. Spray all suspension fasteners with penetrating oil and allow 15-30 minutes soak time
6. Take reference photos of suspension geometry and routing for reassembly

Procedure

1. 1

   Disconnect sway bar end links
   Working on both sides, locate the sway bar end link connecting the sway bar to the lower control arm. Hold the ball stud with a wrench to prevent spinning, then remove the lower nut securing the end link to the control arm. Remove the upper nut securing the end link to the sway bar. Remove both end links completely.
2. 2

   Remove brake caliper and rotor
   Remove the caliper mounting bolts (verify count for the fixed Brembo caliper) and hang the caliper from the chassis using wire or a bungee cord—do not let it hang by the brake hose. Slide the brake rotor off the hub. This provides clearance for ball joint separation and control arm removal.
3. 3

   Disconnect upper ball joint from knuckle
   Locate the upper ball joint retaining nut securing the tapered ball joint stud to the steering knuckle. Remove the cotter pin (if fitted) and the nut. Use a ball joint separator or pickle fork to break the taper between the ball joint stud and knuckle bore. Tap the separator gently with a hammer until the joint releases. Support the knuckle to prevent it from falling.
   ⚠Ball joint taper may release suddenly. Keep hands clear of pinch point between control arm and knuckle.
   Torque spec

   Ball Joint Pinch Bolt50 Nm (37 lb-ft)
4. 4

   Disconnect lower ball joint from knuckle
   Locate the lower ball joint retaining nut securing the tapered ball joint stud to the steering knuckle. Remove the cotter pin (if fitted) and the nut. Use a ball joint separator to break the taper between the lower ball joint stud and knuckle. The knuckle/hub assembly is now free and can be moved aside or removed completely if desired.
   Torque spec

   Ball Joint Pinch Bolt50 Nm (37 lb-ft)
5. 5

   Remove strut assembly from vehicle
   Access the upper coil-over shock mount and locate the upper mounting fastener(s) at the top of each shock tower — verify exact count and type against Viper service manual. Remove these three nuts while supporting the strut from below. At the bottom of the strut, remove the two bolts securing the strut to the lower control arm or knuckle mounting point. Carefully lower and remove the complete strut assembly from the vehicle. Repeat for both sides.
   ⚠Strut assembly is heavy and awkward. Have an assistant support the unit during removal or use a transmission jack.
   Torque spec

   Strut Top Mount Nuts25 Nm (18 lb-ft)
6. 6

   Remove upper control arms
   Locate the two pivot bolts securing each upper control arm to the chassis mounting brackets. These bolts pass through the control arm bushings. Mark the position of any shims or eccentric washers used for alignment adjustment—these must be reinstalled in the same position. Remove both pivot bolts and extract the upper control arm from the vehicle. Repeat for both sides.
   Torque spec

   Upper Control Arm Bolts90 Nm (66 lb-ft)
7. 7

   Remove lower control arms
   Locate the two large pivot bolts securing each lower control arm to the chassis. These are typically the largest fasteners in the front suspension. Mark any shim positions for alignment reference. Remove both pivot bolts and carefully lower the control arm from the vehicle. The sway bar may need to be repositioned for clearance. Repeat for both sides.
   Torque spec

   Lower Control Arm Bolts110 Nm (81 lb-ft)
8. 8

   Disassemble and inspect strut assemblies
   Using a coil spring compressor, carefully compress the coil spring on each strut assembly until tension is relieved from the top mount. Remove the center shaft nut while holding the strut shaft with a wrench or socket. Remove the upper mount, upper spring seat, dust boot, and bump stop (note: coil-over shock does not use a steering bearing plate). Carefully release spring tension and remove the spring. Inspect the strut body for leaks or damage. Inspect the spring for cracks or damage. Replace worn or damaged components including mount bearings, dust boots, and bump stops.
   ⚠️Spring must be fully compressed before removing center shaft nut. Verify compressor is properly engaged and spring is stable before proceeding.
9. 9

   Replace control arm bushings and ball joints
   Using a shop press, remove the old bushings from all four control arms by pressing them out of their bores. Clean the bushing bores thoroughly with a wire brush and inspect for damage or distortion. Press new bushings into the control arms, ensuring they are fully seated and oriented correctly (some bushings have a void or flat spot that must align with the control arm movement axis). Replace ball joints by removing the retaining bolts or pressing out press-fit joints, then install new ball joints per manufacturer instructions. Torque ball joint mounting bolts to specification if bolted style.
10. 10

    Install lower control arms
    Position the rebuilt lower control arms into their chassis mounting points. Insert the pivot bolts finger-tight only at this stage—do not torque them yet. Ensure any alignment shims are reinstalled in their original positions. The control arm should move freely on its pivots. Repeat for both sides.
11. 11

    Install upper control arms
    Position the rebuilt upper control arms into their chassis mounting points. Insert the pivot bolts finger-tight only at this stage—do not torque them yet. Ensure any alignment shims or eccentric washers are reinstalled in their marked positions. The control arm should move freely on its pivots. Repeat for both sides.
12. 12

    Reassemble and install strut assemblies
    Install the new or cleaned bump stop and dust boot onto each strut shaft. Place the coil spring onto the lower spring seat with the spring compressor still engaged. Install the upper spring seat, bearing plate, and new top mount. Align all components and thread the center shaft nut onto the strut shaft. Torque the center shaft nut to specification. Carefully release the spring compressor tension, ensuring the spring seats properly in both upper and lower seats. Remove the compressor.
13. 13

    Install strut assemblies to vehicle
    Lift each strut assembly into position and align the top mount studs with the holes in the strut tower. Install the three top mount nuts and torque to specification. Position the lower end of the strut to its mounting point on the lower control arm or knuckle and install the two mounting bolts. Torque these bolts to specification. Repeat for both sides.
    Torque spec

    Strut Top Mount Nuts25 Nm (18 lb-ft)
14. 14

    Reconnect ball joints to knuckle
    Position the steering knuckle between the upper and lower control arms. Insert the lower ball joint stud into the knuckle and install a new pinch bolt. Insert the upper ball joint stud into the knuckle and install a new pinch bolt. Torque both pinch bolts to specification. Ensure the ball joint studs are fully seated in their tapers before tightening. Repeat for both sides.
    ℹ️Use new pinch bolts if they are locknut or thread-locking style. Do not reuse deformed or stretched bolts.
    Torque spec

    Ball Joint Pinch Bolt50 Nm (37 lb-ft)
15. 15

    Reinstall brake rotors and calipers
    Slide the brake rotor onto the hub and ensure it seats flush. Position the brake caliper over the rotor and align the mounting holes. Install the two caliper mounting bolts and torque to specification. Remove any wire or support used to hang the caliper. Repeat for both sides.
16. 16

    Install sway bar end links
    Insert the sway bar end link ball studs through the sway bar mounting point and the lower control arm mounting point. Install the upper nut finger-tight, then install the lower nut finger-tight. Hold the ball stud with a wrench and torque both nuts to specification. Repeat for both sides.
    Torque spec

    Sway Bar End Link Nuts60 Nm (44 lb-ft)
17. 17

    Load suspension and torque pivot bolts
    Install the front wheels and lower the vehicle until the suspension is at ride height (tires on ground, full vehicle weight on suspension). Alternatively, use an alignment jack or cradle to load the suspension to simulate ride height while the vehicle is still on jack stands. With the suspension loaded, torque the upper control arm pivot bolts to specification, then torque the lower control arm pivot bolts to specification. This is critical—torquing these bolts with the suspension unloaded will cause premature bushing failure.
    ⚠Control arm pivot bolts MUST be torqued at ride height. This is the most critical step for bushing longevity.
    Torque spec

    Upper Control Arm Bolts90 Nm (66 lb-ft)

    Lower Control Arm Bolts110 Nm (81 lb-ft)
18. 18

    Final torque wheel lug nuts
    With the vehicle on the ground, torque all wheel lug nuts to specification in a star pattern. Verify all suspension fasteners are tight and no tools or parts have been left in the wheel wells.

Reassembly

1. All suspension pivot bolts (upper and lower control arms) must be torqued at ride height to prevent bushing damage
2. Use new ball joint pinch bolts if they are self-locking or deformed from removal
3. Reinstall alignment shims and eccentric washers in their original marked positions
4. Verify brake calipers are properly secured and brake pedal is firm before moving vehicle

Verification

• Bounce each corner of the vehicle and verify suspension moves smoothly without binding or unusual noises
• Verify no suspension components contact the chassis, brake lines, or wheel wells through full suspension travel
• Check that steering wheel can be turned lock-to-lock without binding
• Test drive at low speed in a safe area and verify no unusual noises, vibrations, or handling issues
• Have front end alignment performed by a professional shop immediately—vehicle will not track straight until aligned
• After 50-100 miles, re-torque all suspension fasteners and verify no looseness has developed

Related trouble codes on this vehicle

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