PT Cruiser 2006-2007

Lower Control Arms

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Bushing Replacement



Clevis Bushing
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the lower control arm assembly
  4.  
  5. Install the Bushing Remover Tool 6877 and Bushing Receiver Tool 6876 on Special Tool C-4212-F.
  6.  
  7. Position the lower control arm on the assembled removal tools.
    NOTE
    Be sure the Bushing Receiver Tool 6876 is square on the lower control arm and Bushing Remover Tool 6877 is positioned correctly on the clevis bushing.

  8.  
  9. Tighten Special Tool C-4212-F to press the bushing from the lower control arm.

    Click image to see an enlarged view

    Fig. Removing the clevis bushing from the lower control arm



    Click image to see an enlarged view

    Fig. Installing the clevis bushing to the lower control arm

  10.  

To assemble:

  1. Position the Bushing Installer Tool 6877 onto the screw portion of special Tool C-4212-F.
  2.  
  3. Start the new bushing into the lower control arm hole-s machined surface side by hand, making sure it is square with its mounting hole with the void in the rubber portion facing away from the ball joint.
  4.  
  5. Assemble special Tools 6876 and 6877; then, position the lower control arm on the assembly, making sure that the tools are aligned.
  6.  
  7. Tighten special Tool C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface.
  8.  
  9. Install the lower control arm assembly.
  10.  

Front Isolator Bushing
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the lower control arm assembly
  4.  
  5. Install the Bushing Remover Tool 6602-5 and Bushing Receiver Tool MB-990799 on Special Tool C-4212-F.
  6.  
  7. Position the lower control arm on the assembled removal tools.
    NOTE
    Be sure the Bushing Receiver Tool MB-990799 is square on the lower control arm and Bushing Remover Tool 6602-5 is positioned correctly on the isolator bushing.

  8.  
  9. Tighten Special Tool C-4212-F to press the bushing from the lower control arm.

    Click image to see an enlarged view

    Fig. Removing the front isolator bushing from the lower control arm



    Click image to see an enlarged view

    Fig. Installing the front isolator bushing to the lower control arm

  10.  

To assemble:

  1. Position the Bushing Installer Tool 6876 onto the screw portion of Special Tool C-4212-F.
  2.  
  3. Start the new bushing into the lower control arm hole machined surface side by hand, making sure it is square with its mounting hole.
  4.  
  5. Assemble Special Tools 6758, 6876 and C-4212-F; then, position the lower control arm on the assembly, making sure that the tools are aligned.
  6.  
  7. Tighten Special Tool C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface.
  8.  
  9. Install the lower control arm assembly.
  10.  

Rear Isolator Bushing
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the lower control arm assembly
  4.  
  5. Install the Bushing Remover Tool 6756 and Bushing Receiver Tool C-4366-2 on Special Tool C-4212-F.
  6.  
  7. Position the lower control arm on the assembled removal tools.
    NOTE
    Be sure the Bushing Receiver Tool C-4366-2 is square on the lower control arm and Bushing Remover Tool 6756 is positioned correctly on the isolator bushing.

  8.  
  9. Tighten Special Tool C-4212-F to press the bushing from the lower control arm.

    Click image to see an enlarged view

    Fig. Removing the rear isolator bushing from the lower control arm



    Click image to see an enlarged view

    Fig. Positioning the rear isolator bushing to the lower control arm



    Click image to see an enlarged view

    Fig. Installing the rear isolator bushing to the lower control arm

  10.  

To assemble:

  1. Position the Bushing Installer Tool 6760 onto the screw portion of special Tool C-4212-F.
  2.  
  3. Start the new bushing into the lower control arm hole-s machined surface side by hand, making sure it is square with its mounting hole with the void in the rubber portion facing away from the ball joint.
  4.  
  5. Assemble Special Tools 6760 and 6756; then, position the lower control arm on the assembly, making sure that the tools are aligned.
  6.  
  7. Tighten Special Tool C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface.
  8.  
  9. Install the lower control arm assembly.
  10.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise the vehicle.
  4.  
  5. Remove the front tire and wheel assembly.
  6.  
  7. Remove both stabilizer bar links from the vehicle. Remove each link by holding the upper retainer/nut with a wrench and turning the link bolt.
  8.  
  9. Rotate the forward ends of the stabilizer bar downward. It may be necessary to loosen the stabilizer bar cushion retainer bolts a little to ease any turning resistance.
  10.  
  11. Remove the nut and pinch bolt clamping the ball joint stud to the steering knuckle.
    CAUTION
    After removing the steering knuckle from the ball joint stud, do not pull outward on the knuckle. Pulling the steering knuckle outward at this point can separate the inner CV-joint on the driveshaft.


    WARNING
    Use caution when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get cut.

  12.  
  13. Separate the ball joint stud from the steering knuckle by prying down on lower control arm and up against the ball joint boss on the steering knuckle.
  14.  
  15. If the right lower control arm is being serviced, perform the following:
    1. Remove the screws fastening the front fascia to the reinforcement as necessary in order to access the drive belt splash shield forward fastener screw.
    2.  
    3. Remove the drive belt splash shield fasteners. Remove the shield.
    4.  
    5. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle. Remove the washer behind the strut from the torque strut bolt.
    6.  
    7. Remove the bolts mounting the engine torque strut in place, then remove the engine torque strut from the vehicle.
    8.  

  16.  
  17. Remove the front pivot bolt attaching the lower control arm to the front suspension crossmember.
  18.  
  19. Remove the rear pivot bolt attaching the lower control arm to the front suspension crossmember and frame rail.
  20.  
  21. Remove the lower control arm from the crossmember.
  22.  

To install:

Click image to see an enlarged view

Fig. Lower control arm mounting bolts and location

  1. Position the lower control arm into the crossmember.
  2.  
  3. Install, but do not fully tighten, the rear pivot bolt attaching the lower control arm to the front suspension crossmember and frame rail.
  4.  
  5. Install, but do not fully tighten, the front pivot bolt attaching the lower control arm to the front suspension crossmember.
  6.  
  7. With no weight on the lower control arm, tighten the lower control arm rear pivot (and suspension crossmember) bolt to a torque of 185 ft. lbs. (250 Nm).
  8.  
  9. Tighten the lower control arm front pivot bolt to a torque of 125 ft. lbs. (170 Nm).
  10.  
  11. Install the ball joint stud into the steering knuckle aligning the bolt hole in the knuckle boss with the notch formed in the side of the ball joint stud.
  12.  
  13. If the right lower control arm has been serviced, perform the following:
    1. Install the engine torque strut. To properly align and tighten the torque strut, install the washer on the end of the stud extending from the torque strut bolt.
    2.  
    3. Install the pencil strut to the right front corner of the crossmember and body of the vehicle. Tighten the pencil strut nuts to a torque of 43 ft. lbs. (58 Nm).
    4.  
    5. Install the drive belt splash shield and fasteners.
    6.  
    7. Install the screws fastening the front fascia to the reinforcement.
    8.  

  14.  
  15. Install a new ball joint stud pinch bolt and nut. Tighten the nut to a torque of 70 ft. lbs. (95 Nm).
  16.  
  17. Rotate the forward ends of the stabilizer bar into mounting position.
  18.  
  19. Clean the threads of the stabilizer bar link bolts, then apply MOPAR® Lock And Seal or equivalent to the threads.
  20.  
  21. Install both stabilizer bar links back on vehicle. Start each stabilizer bar link bolt with bushing from the bottom, through the stabilizer bar, inner link bushings, lower control arm, and into the upper retainer/nut and bushing. Do not fully tighten the link assemblies at this time.
  22.  
  23. Lower the vehicle to ground level.
    NOTE
    It may be necessary to put the vehicle on a platform hoist or alignment rack to gain access to the stabilizer bar mounting bolts with the vehicle at curb height.

  24.  
  25. Tighten each stabilizer bar link by holding the upper retainer/nut with a wrench and turning the link bolt. Tighten each link bolt to a torque of 250 inch lbs. (28 Nm)).
  26.  
  27. If previously loosened, tighten the stabilizer bar cushion retainer bolts to a torque of 250 inch lbs. (28 Nm).
  28.  

 
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