Astro, Safari 1997-2005

Lower Control Arms

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Bushing Replacement



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove lower control arm and place it in vise.
  4.  
  5. Use a punch to unbend the crimps on the front bushing.
  6.  
  7. Use tools J 36618-2, J 9519-23 and J 36618-1 to remove the front bushing from the arm.
  8.  
  9. Use tools J 36618-5, J 36618-3, J 36618-2 and J 9519-23 to remove the rear bushing from the arm.
  10.  

To install:

  1. Install the front bushing using tools J 36618 and J 5919-23 and bend the crimps back into position to retain the bushing.
  2.  
  3. Install the rear bushing using tools J 36618 and J 5919-23 .
  4.  
  5. Install the lower control arm.

    Click image to see an enlarged view

    Fig. You need a variety of special tools to replace the control arm bushing

  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove lower control arm and place it in vise.
  4.  
  5. Use a punch to unbend the crimps on the front bushing.
  6.  
  7. Use tools J-36618-2, J-9519-23 and J-36618-1 to remove the front bushing from the arm.
  8.  
  9. Use tools J-36618-5, J-36618-3, J-36618-2 and J-9519-23 to remove the rear bushing from the arm.

    Click image to see an enlarged view

    Fig. You need a variety of special tools to replace the control arm bushing

  10.  

To install:

  1. Install the front bushing using tools J-36618 and J-5919-23 and bend the crimps back into position to retain the bushing.
  2.  
  3. Install the rear bushing using tools J-36618 and J-5919-23 .
  4.  
  5. Install the lower control arm.
  6.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove coil spring.
  4.  
  5. Disconnect lower ball joint from the steering knuckle using special tool J-23742.
  6.  
  7. Remove lower control arm from the vehicle.
  8.  

To install:

  1. Install lower control arm.
  2.  
  3. Install lower ball joint stud into the steering knuckle.
  4.  
  5. Install ball joint-to-steering knuckle nut and tighten to 90 ft. lbs. (125 Nm).
  6.  
  7. Install new cotter pin to the lower ball joint stud.
  8.  
  9. Install coil spring.
  10.  
  11. Align the vehicle.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Tools Needed: universal tie rod separator J-24319-B, torsion bar unloader J-36202, upper ball joint separator J-36607, lower control arm bushing service kit J-36618 (if the control arm bushing are being replaced) and ball joint C-clamp J-9519-23. Parts Needed: whether or not the control arm or bushing are being replaced, NEW control arm retaining nut should be used once the old ones have been loosened and removed.

  2.  
  3. Remove front wheels.
  4.  
  5. Remove 2 bolts from the front splash shield and pivot it in order to gain access to the tie rod.
  6.  
  7. Remove the torsion bar.
  8.  
  9. Remove stabilizer bar from the control arm (keeping all of the link hardware sorted for proper installation). If necessary, completely remove the bar from the vehicle for access.
  10.  
  11. Remove shock absorber.
  12.  
  13. Remove the brake rotor.
  14.  
  15. Remove outer halfshaft nut and washer.
  16.  
  17. Disengage the halfshaft from the from the wheel hub and bearing.
  18.  
  19. Remove the outer tie rod cotter pin and retaining nut.
  20.  
  21. Disconnect the wheel speed sensor electrical connector.
  22.  
  23. Remove the wheel speed sensor bracket retaining bolts at the frame and upper control arm.
  24.  
  25. Disconnect the wheel speed sensor wiring harness clips form the upper control arm.
  26.  
  27. Remove the upper ball joint cotter pin and retaining nut.
  28.  
  29. Install special tool J-36607 to the upper control arm and steering knuckle and disconnect the upper control arm from the steering knuckle.
  30.  
  31. Remove lower ball joint cotter pin, nut and ball joint from the control arm using a ball joint separator.
  32.  
  33. Remove nuts and bolts and lower control arm. Note the direction which the control arm retaining bolts are facing for installation purposes.
  34.  

To install:

  1. Install lower control arm brace to the lower control arm and place the assembly into the vehicle. Position the front leg of the lower control arm into the crossmember before installing the rear leg into the frame bracket.
  2.  
  3. Install control arm bolts (facing in the direction as noted during removal or shown in the accompanying illustration) with NEW nuts.
    NOTE
    The control arm retainers MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nuts now, then installing the remaining components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure front suspension is at actual ride height compression. If you are unsure, it is best to start the nuts now and tighten them to specification once the vehicle is lowered.



    Click image to see an enlarged view

    Fig. Exploded view of the lower control arm assembly mounting

  4.  
  5. Install ball joint stud in the knuckle.
  6.  
  7. With the suspension at the correct height, tighten the control arm retaining nuts to 98 ft. lbs. (133 Nm).
    NOTE
    The lower ball joint retaining nut MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nut now, then installing the remaining components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure the FULL WEIGHT of the vehicle front end is on the suspension.

  8.  
  9. Install lower ball joint-to-control arm nut, then tighten the nut to 95 ft. lbs. (128 Nm) with the suspension at normal ride height and compression.
  10.  
  11. Install new cotter pin to the castellated nut. Tighten the nut (but no more than an additional 1 / 6 turn) in order to align the cotter pin. DO NOT loosen the nut from the specified torque.
  12.  
  13. Install adjuster arm by sliding the adapter forward, over the torsion bar to install the sides of the nut. Load the torsion bar and install the adjuster bolt aligning the installation mark.
  14.  
  15. Install drive axle through the hub and bearing assembly.
  16.  
  17. Tighten the hub and bearing assembly retaining bolts.
  18.  
  19. Install halfshaft nut and washer.
  20.  
  21. Install inner tie rod end to the relay rod.
  22.  
  23. Install shock absorber.
  24.  
  25. Install stabilizer bar, if removed.
  26.  
  27. Install stabilizer link(s) to the control arm(s).
  28.  
  29. Install torsion bar.
  30.  
  31. Install splash shield.
  32.  
  33. Install front wheels.
  34.  
  35. Recheck all fasteners for proper torque and installation before road testing.
  36.  
  37. Refill the differential if any fluid was lost.
  38.  
  39. Check and adjust the front end alignment, as necessary.
  40.  

 
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