Express, Savana, G1500, G2500, G3500, 1998-2005

Lower Control Arms

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Bushing Replacement



Front Bushing
  1. On 15 and 25 Series, the bushings are not replaceable. If they are damaged, the control arm will have to be replaced.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Remove or disconnect the following:

    Wheel
     
    Lower control arm
     
    Unbend the crimps with a punch on the front bushing
     

  6.  
  7. Press out the bushings with tools J-36618-2, J-9519-23, J-36618-4 and 36618-1.
  8.  

To install:

  1. Lubricate the outer case of the bushing.
  2.  
  3. Install or connect the following:

    Bushing into control arm
     

  4.  
  5. Press in the bushings with tools J-36618-2, J-9519-23, J-36618-4 and 36618-1 until the bushing is seated in.
  6.  
  7. After bushing is installed crimp it in place.

    Control arm and mounting bolts. Torque the front nut first then the rear to 140 ft lbs. (190 Nm)
     
    Wheel
     

  8.  

Rear Bushing
  1. On 15 and 25 Series, the bushings are not replaceable. If they are damaged, the control arm will have to be replaced.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Remove or disconnect the following:

    Wheel
     
    Lower control arm
     

  6.  
  7. Press out the bushings with tools. J-36618-5, J-9519-23, J-36618-3 and J-36618-2. There are no crimps.
  8.  

To install:

  1. Lubricate the outer case of the bushing.
  2.  
  3. Install or connect the following:

    Bushing into control arm
     

  4.  
  5. Press in the bushings with tools J-36618-5, J-9519-23, J-36618-3 and J-36618-2. There are no crimps.

    Control arm and mounting bolts. Torque the front nut first then the rear to 140 ft lbs. (190 Nm)
     
    Wheel
     

  6.  

Removal & Installation




NOTE
Special tools J-36202, J-36618-1, J-36618-2, J-36618-3, J-36618-4, J-36618-5, and J-9519-23, or their equivalents, are necessary for this procedure.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Wheel
     

  4.  
  5. Matchmark the both torsion bar adjustment bolt positions.
  6.  
  7. Using tool J-36202, increase the tension on the adjusting arm.

    Adjustment bolt and retaining plate, and move the tool aside
     

  8.  
  9. Slide the torsion bars forward.

    Adjusting arm
     
    Splash shield from the knuckle, if equipped
     
    Hub nut and washer. Insert a long drift or dowel through the vanes in the brake rotor to hold the rotor in place.
     
    Axle shaft out of the hub
     
    Brake caliper and wire it aside
     
    Rotor
     
    Shock absorber from control arm
     
    Inner tie rod end from the relay rod
     

  10.  
  11. Support the lower control arm with a floor jack.

    Stabilizer bar from the control arm
     
    Cotter pin from the lower ball stud and loosen the nut
     
    Ball joint from control arm
     
    Control arm-to-frame bracket bolts, nuts and washers
     
    Lower control arm and torsion bar as a unit
     

  12.  
  13. Separate the control arm and torsion bar.
  14.  

To install:

  1. Install or connect the following:
    NOTE
    Do not tighten the bolts yet. The bolts must be torqued with the truck at its proper ride height.



    Control arm assembly into position. Insert the front leg of the control arm into the crossmember first, then the rear leg into the frame bracket.
     
    Mounting bolts, front one first. The bolts must be installed with the front bolt head heads towards the front of the truck and the rear bolt head towards the rear of the truck!
     



    Ball joint into the knuckle. Torque the nut to 94 ft lbs. (128 Nm).
     
    Adjuster arm
     

  2.  
  3. Using tool J-36202, increase tension on both torsion bars.

    Adjustment retainer plate and bolt on both torsion bars and set to marked positions. Release the tension on the torsion bar until the load is taken up by the adjustment bolt.
     
    Wheel
     

  4.  
  5. Lower the truck. Once the weight of the truck is on the wheels. Torque the bolts to 121 ft. lbs. (165 Nm).
  6.  

2-Wheel Drive
  1. Raise and support the vehicle.
  2.  
  3. Remove or disconnect the following:

    Tire and wheel assembly
     
    Coil spring on vehicles with rack and pinion steering
     
    Torsion bar on vehicles with recirculating ball steering
     
    Shock absorber
     
    Front stabilizer shaft link
     
    Lower control arm nuts and the washers
     
    Lower control arm bolts
     
    Lower ball joint stud nut
     
    Lower ball joint stud from the steering knuckle
     
    Lower control arm

    Click image to see an enlarged view

    Fig. 2WD lower control arm-1500 series



    Click image to see an enlarged view

    Fig. 2WD lower control arm-2500 series

     

  4.  

To install:

  1. Install or connect the following:

    Lower control arm
     
    Ball joint stud to the steering knuckle
     
    Lower ball joint stud nut. Tighten the lower ball joint stud nut to 74 ft. lbs. (100 Nm)
     
    Front coil spring or torsion bar
     
    Lower control arm bolt
     
    Lower control arm nuts and the washers. Tighten the nuts to 129 ft. lbs. (175 Nm)
     
    Front stabilizer shaft link.
     
    Shock absorber
     
    Tire and wheel assembly
     

  2.  
  3. Remove the safety stands. Lower the vehicle. Verify the wheel alignment.
  4.  

4-Wheel Drive
  1. Raise and support the vehicle.
  2.  
  3. Remove or disconnect the following:

    Tire and wheel assembly
     
    Stabilizer shaft links from the lower control arm
     
    Shock absorber nut and the bolt
     
    Torsion bars
     
    Halfshaft
     
    Lower ball joint stud nut
     
    Lower ball joint stud from the steering knuckle
     
    Lower control arm nuts and the washers
     
    Lower control arm bolts
     
    Lower control arm
     

  4.  

To install:

Click image to see an enlarged view

Fig. 4WD lower control arm-1500 series



Lower control arm
 
Lower control arm bolts
 
Washers with the shoulder facing the arm
 
Nuts and tighten to 129 ft. lbs. (175 Nm)
 
Halfshaft
 
Lower ball joint stud to the steering knuckle. Install the nut to the ball joint stud. Tighten the nut to 74 ft. lbs. (100 Nm).
 
Torsion bars
 
Shock absorber through nut and bolt
 
Stabilizer shaft links to the lower control arm
 
RTD link rod to the sensor (if equipped)
 
Tire and wheel assembly
 

  1. Remove the safety stands. Lower the vehicle. Verify the wheel alignment.
  2.  

 
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