Astro, Safari 1997-2005

Upper Control Arms

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Bushing Replacement



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove upper control arm and place it in a vice.
  4.  
  5. Remove upper control arm shaft nuts and retainers.
  6.  
  7. Remove upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing.
  8.  
  9. Remove upper control arm shaft.

    Click image to see an enlarged view

    Fig. Removing the upper control arm bushings using tool J-22269-1-2WD

  10.  

To install:

  1. Install upper control arm shaft.
  2.  
  3. Install upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing.
  4.  
  5. Tighten J 22269-1 until the bushing is positioned on the shaft and the control arm as shown in the accompanying illustration. The measurement should be 0.48-0.52 inch (12.8-13.8mm) at both sides when the properly installed.
  6.  
  7. Install upper control arm shaft nuts and retainers. Tighten to 85 ft. lbs. (115 Nm).
  8.  
  9. Install upper control arm.

    Click image to see an enlarged view

    Fig. The bushing should be positioned as follows when correctly installed-2WD

  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove upper control arm.
  4.  
  5. Remove bushings from the arm.
  6.  
  7. Installation is the reverse of removal.
  8.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
  4.  
  5. Disconnect negative battery cable.
  6.  
  7. Remove wheel.
  8.  
  9. Remove wheel speed sensor harness bracket retaining bolt and nut, if equipped.
  10.  
  11. Remove steering knuckle from upper control arm ball joint.
  12.  
  13. Remove mounting nuts/bolts and shims.
    NOTE
    Make sure to note the location of the control arm shims prior to removal so that they may be installed in their original positions.

  14.  
  15. Remove upper control arm.
  16.  

To install:

  1. Install upper control arm.
    NOTE
    Always tighten nut on the thinner shim pack first.

  2.  
  3. Install mounting nuts/bolts and shims. Torque the nuts to 81 ft. lbs. (110 Nm).
  4.  
  5. Install steering knuckle to upper control arm ball joint.
  6.  
  7. Install new cotter pin.
    NOTE
    Tighten the nut to align the hole never loosen.

  8.  
  9. Install wheel speed sensor harness bracket retaining bolt and nut, if equipped.
  10.  
  11. Install wheel.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Support the control arm with jackstands.
  4.  
  5. Remove tire and wheel assembly.
  6.  
  7. Remove brake hose bracket nut and bolt.
  8.  
  9. Remove speed sensor bracket nut and bolt.
  10.  
  11. Remove upper ball joint from the steering knuckle.
  12.  
  13. Remove upper control arm cam hardware nuts, cams, and bolts.
  14.  
  15. Remove upper control arm.

    Click image to see an enlarged view

    Fig. Exploded view of the upper control arm mounting bolts.

  16.  

To install:

  1. Install upper control arm.
  2.  
  3. Install upper control arm cam hardware bolts and the cams, making sure the bolt heads are opposed inside the bracket and that the cam lobes point down.
    NOTE
    Tighten the nuts with the control arm at Z height.

  4.  
  5. Install new upper control arm cam hardware nuts. Tighten the front nut first, then the rear nut to 103 ft. lbs. (140 Nm).
  6.  
  7. Install the remaining components and check the wheel alignment.
  8.  

 
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