Disassembly and Assembly

DISASSEMBLY - UPPER CONTROL ARM (ISOLATOR BUSHINGS)
For replacement of the upper control arm isolator bushings, the upper control arm must be removed from the vehicle.

CAUTION: The jaws of the vise must be covered with protective caps to protect the surface of the control arm from damage.





1. Clamp the upper control arm securely in a vise.





2. Remove the nut and washer from each end of the upper control arm pivot bar.





3. Install Remover, Special Tool 6969-5, in the mounting hole of the upper control arm pivot bar as shown. When installing the tool, install it so the attachment pin is installed from the top down as shown in the figure. This will prevent the pin from falling out of the tool during bushing removal.
4. Install Nut, Special Tool 6969-4, on the end of the upper control arm pivot bar as shown.





5. Assemble Bolt and Nut, thrust washer, and cup, special tools 6969-3, 6969-1 and 6969-2 to form the bushing remover.





6. Install the assembled pieces of the bushing remover on the upper control arm pivot bar as shown. The tool is installed by threading the Bolt, Special Tool 6969-3, into Nut, Special Tool 6969-4.
7. Remove the isolator bushing. To do this, hold the bolt from turning while rotating the nut on the bolt threads clockwise. This will pull both the isolator bushing and pivot bar out of the upper control arm.
8. Remove the special tools, bushing and washer from the end of the pivot bar. Leave the opposite side washer on the pivot bar.
9. Place the pivot bar and remaining pivot bar washer back through the control arm and remaining isolator bushing.





10. Install Remover, Special Tool 6969-5, and Nut, Special Tool 6969-4, in the mounting hole on the pivot bar to remove the remaining isolator bushing.





11. Install the assembled pieces of the bushing remover on the upper control arm pivot bar at the remaining bushing as shown.
12. Remove the second isolator bushing. 1b do this, hold the bolt from turning while rotating the nut on the bolt threads clockwise. This will pull the second isolator bushing and pivot bar out of the upper control arm at the same time.
13. Remove the tools from the pivot bar.

INSPECTION
Inspect the upper control arm for the following:
- Inspect the upper control arm for any signs of damage. If the control arm shows any sign of damage the upper control arm must be replaced. Do not attempt to repair or straighten a broken or bent upper control arm.
- Inspect the upper control arm pivot bar for any signs of damage. Do not attempt to repair or straighten a broken or bent upper control arm pivot bar.
- Inspect both control arm isolator bushings for severe deterioration. These bushings can be serviced separately.
- Inspect the ball joint per the procedure.
- Inspect the ball joint grease seal (boot) for cuts or splits. It can be serviced separately.

ASSEMBLY - UPPER CONTROL ARM (ISOLATOR BUSHINGS)





1. Start the first isolator bushing into the control arm bushing bore by hand. Be sure the bushing is installed straight.
2. Place the pivot bar washers on each end of the pivot bar.





3. Slide the pivot bar through the control arm and bushing as shown.





4. Place Installer, Special Tool 6969-6, over the mounting hole in the upper control arm pivot bar as shown and then install the attachment pin.
5. Square the Installer, Special Tool 6969-6, up against the control arm bushing boss.
6. Install the Nut, Special Tool 6969-4, on the end of the pivot bar.





7. Assemble Bolt and Nut, thrust washer, and cup, special tools 6969-3, 6969-1 and 6969-7 to form the bushing installer.
8. Install the assembled pieces of the bushing installer on the upper control arm pivot bar as shown. The tool is installed by threading the Bolt, Special Tool 6969-3, into Nut, Special Tool 6969-4.
9. Install the isolator bushing. To do this, hold the bolt from turning while rotating the nut on the bolt threads clockwise. This will press the isolator bushing into the upper control arm.





10. Press the bushing into the arm until the outer bushing flange bottoms against the control arm bushing boss. Do not leave a gap.
11. Remove the special tools.
12. Install the second isolator bushing into its bore by hand. Make sure the pivot bar washer is on the bar before placing the bushing on the bar.





13. Place Installer, Special Tool 6969-6, over the mounting hole in the upper control arm pivot bar and then install the attachment pin.
14. Square the Installer, Special Tool 6969-6, up against the control arm bushing boss.
15. Install the Nut, Special Tool 6969-4, on the end of the pivot bar.





16. Install the assembled pieces of the bushing installer removed from the opposite end of the bar onto the end of the pivot bar needing bushing installation. The tool is installed by threading the Bolt, Special Tool 6969-3, into Nut, Special Tool 6969-4
17. Install the isolator bushing. To do this, hold the bolt from turning while rotating the nut on the bolt threads clockwise. This will press the isolator bushing into the upper control arm.
18. Press the bushing into the arm until the outer bushing flange bottoms against the control arm bushing boss. Do not leave a gap.
19. Remove the special tools.
20. Install a nut and washer on each end of the pivot bar. Tighten the nuts just enough to hold the pivot bar in place. Do not fully tighten at this time. This must be done once the arm is back on the vehicle and the vehicle is positioned at design height.
21. Install the upper control arm on the vehicle.