GM Full Size Vans 1987-1997 Repair Guide

Lower Control Arm

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REMOVAL & INSTALLATION



See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the lower control arm-1987-95 models

  1. Raise and support the van on jackstands.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the caliper assembly. Do not allow the caliper to hang by the brake hose.
  6.  
  7. Remove the spring assembly. Refer to the spring removal and installation procedure.
  8.  
  9. Support the inboard end of the control arm after spring removal.
  10.  
  11. Remove the cotter pin from the lower ball stud and loosen the nut.
  12.  
  13. Loosen the lower ball stud in the steering knuckle using a ball joint stud removal tool. When the stud is loose, remove the nut from the stud. It may be necessary to remove the brake caliper and wire it to the frame to gain clearance.
  14.  
  15. Remove the lower control arm.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the lower control arm-1996-97 models

To install:
  1. Install the lower control arm. Tighten the U-bolts to 65 ft. lbs. (88 Nm) on 10/1500 and 20/2500 series; 85 ft. lbs. (115 Nm) on 30/3500 series on 1987-95 models and 115 ft. lbs. (155 Nm) on 1996-97 models.
  2.  
  3. Install the ball stud nut. Tighten the nut to 90 ft. lbs. (122 Nm) for 10/1500 series 130 ft. lbs. (176 Nm) for 30/3500 series 1987-95 models and on 1996-97 models, install the ball stud nut and tighten it to 94 ft. lbs. (128 Nm) on the lower nut and 74 ft. lbs. (100 Nm) on the upper nut.
  4.  
  5. Install the brake caliper.
  6.  
  7. Install the spring. Refer to the spring removal and installation procedure in this section.
  8.  

CONTROL ARM BUSHING REPLACEMENT



10/1500 Series With Gasoline Engines

See Figures 3 and 4



Click image to see an enlarged view

Fig. Fig. 3: Removing or installing the lower control arm bushings-G/101500 and G20/2500 models

The following tools, or their equivalents, are necessary for this procedure: J-24435-1, J-24435-3, J-24435-4, J-24435-5 and J-24435-7.

  1. Remove the upper control arm as explained earlier in this section.
  2.  
  3. Remove the pivot shaft nuts and washers.
  4.  
  5. Assemble tool J-24435-1, J-24435-3, and J-24435-7 on the control arm. Tighten the tool until the front bushing is forced out.
  6.  
  7. Remove the pivot shaft.
  8.  
  9. Use the forcing procedure to remove the rear bushing.
  10.  

To install:
  1. Position the new front bushing in the arm and assemble tools J-24435-4, J-24435-5 and J-24435-7. Force the bushing into place until it is fully seated.
  2.  
  3. Install the pivot shaft.
  4.  
  5. Install the nuts and washers. Tighten the nuts to 115 ft. lbs. (156 Nm).
  6.  
  7. Repeat the forcing procedure to install the rear bushing.
  8.  
  9. Stake the bushings in at least 2 places.
  10.  
  11. Install the lower control arm.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: View of the lower control arm pivot shaft on the G10/1500 and G20/2500 models with gasoline engines

20/2500 Series With Gasoline Engines
  1. Raise and support the front end on jackstands.
  2.  
  3. Take up the weight of the suspension with a floor jack positioned under the lower control arm as near to the ball joint as possible.
  4.  
  5. Loosen, but do not remove, the pivot shaft-to-frame nuts.
  6.  
  7. Tape together and matchmark each shim pack's position for exact installation.
  8.  
  9. Install a chain over the control arm, inboard of the stabilizer bar and outboard of the shock absorber to hold the control arm close to the crossmember.
  10.  
  11. Remove the pivot shaft nuts, bolts and spacers.
  12.  
  13. Remove the grease fittings and unscrew the bushings from the control arm.
  14.  
  15. Remove the pivot shaft. Discard the seals.
  16.  

To install:
  1. Install new seals on the pivot shaft.
  2.  
  3. Slide the shaft into the arm.
  4.  
  5. Start the bushings into the arm and center the shaft in the bushings. Hand tighten the bushings to make sure the shaft doesn't bind.
  6.  
  7. Tighten the bushings to 190 ft. lbs. (257 Nm).
  8.  
  9. Check the pivot shaft for free rotation.
  10.  
  11. Install the grease fittings and lubricate the bushings.
  12.  
  13. Position the control arm on the frame and install the shim packs, spacers, nuts and bolts. Tighten the nuts to 105 ft. lbs. (142 Nm) on 1987-95 models and 115 ft. lbs. (155 Nm) on 1996-97 models.
  14.  
  15. Remove the chain and install the wheel.
  16.  
  17. Have the alignment checked.
  18.  

30/3500 Series With Gasoline Engines

See Figure 5



Click image to see an enlarged view

Fig. Fig. 5: Centering the lower control arm shaft on the G30/3500 models

  1. Remove the lower control arm.
  2.  
  3. Remove the grease fittings and unscrew the bushings.
  4.  
  5. Slide out the pivot shaft.
  6.  
  7. Discard the old seals.
  8.  

To install:
  1. Install new seals on the pivot shaft.
  2.  
  3. Slide the shaft into the arm.
  4.  
  5. Start the bushings into the arm and center the shaft in the bushings. Hand tighten the bushings to make sure the shaft doesn't bind.
  6.  
  7. Tighten the bushings to 280 ft. lbs. (380 Nm).
  8.  
  9. Check the pivot shaft for free rotation.
  10.  
  11. Install the grease fittings and lubricate the bushings.
  12.  
  13. Install the lower arm.
  14.  

20/2500 Series With Diesel Engines

See Figures 6 and 7



Click image to see an enlarged view

Fig. Fig. 6: Removing the lower control arm bushing - G20/2500 models with diesel engines

  1. Remove the lower control arm as explained earlier in this Section.
  2.  
  3. Assemble tools J-24435-7, J-24435-3, and J-24435-1 on the control arm. Tighten the tool until the front bushing is forced out.
  4.  
  5. Remove the pivot shaft.
  6.  
  7. Repeat the forcing procedure for the other bushing.
  8.  

To install:


Click image to see an enlarged view

Fig. Fig. 7: Installing the lower control arm bushing - G20/2500 models with diesel engines

  1. Position the new front bushing in the arm and assemble tools J-24435-4, J-24435-5 and J-24435-7. Force the bushing into place until it is fully seated.
  2.  
  3. Install the pivot shaft.
  4.  
  5. Repeat the forcing procedure to install the rear bushing.
  6.  
  7. Install the lower control arm.
  8.  

 
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