Front Lower Control Arm Replacement (4WD with Z56)

Single Use Fasteners and Components Front Wheel Drive Shaft Nut Front Wheel Hub Bolt [4x] Front Wheel Hub Seal [2x] Special Tools Disc Brakes CH-41013 Rotor Resurfacing Kit CH-42450-A Wheel Hub Resurfacing Kit Equivalent regional tools: Special Tools Wheel Drive Shafts DT-45859 Axle Remover Equivalent regional tools: Special Tools. Front Suspension CH-43631 Ball Joint Separator Equivalent regional tools: Special Tools

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

Brake Dust Warning Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Raise and support the vehicle. Lifting and Jacking the Vehicle

Front Lower Control Arm Replacement (4WD with Z56) — figure 1

3. {Without RC1} Remove the underbody skid shield: 3.1. Underbody Skid Shield Bolt (1) » Remove [4x] 3.2. Underbody Skid Shield (2) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 2

Note

The proper position of the underbody skid shield is between the underbody splash shield and the front frame.

4. {With RC1} Remove the underbody skid shield: 4.1. Underbody Skid Shield Bolt (1) » Remove [2x] 4.2. Underbody Splash Shield Bolt (2) » Remove [2x] 4.3. Underbody Skid Shield (3) » Remove
5. Remove the front tire and wheel assembly. Tire and Wheel Removal and Installation
6. Have an assistant apply the brakes.

Front Lower Control Arm Replacement (4WD with Z56) — figure 3

Caution

DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.

7. Front Wheel Drive Shaft Nut (1) » Remove and DISCARD

Front Lower Control Arm Replacement (4WD with Z56) — figure 4

8. Install the DT-45859 Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
9. Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
10. Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.

Front Lower Control Arm Replacement (4WD with Z56) — figure 5

11. Front Brake Hose Bracket Bolt (1) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 6

12. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 7

13. { If equipped } Front Disc Brake Pad Wear Sensor Retainer (2) » Remove
14. { If equipped } Position the front disc brake pad wear sensor wiring harness (1) out of the way.

Front Lower Control Arm Replacement (4WD with Z56) — figure 8

15. Front Brake Caliper Bolt (2) » Remove [2x]

Caution

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

16. Remove the brake caliper and support with heavy mechanics wire. (1)

Front Lower Control Arm Replacement (4WD with Z56) — figure 9

17. Front Brake Rotor Bolt (1) » Remove
18. Front Brake Rotor (2) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 10

19. Front Wheel Speed Sensor Bolt (2) » Remove
20. Front Wheel Speed Sensor Wiring Harness (1) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 11

21. Steering Linkage Outer Tie Rod Nut (1) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 12

Caution

Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.

22. Using CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.

Front Lower Control Arm Replacement (4WD with Z56) — figure 13

23. Reposition the front wheel drive half shaft as necessary to access the front wheel hub bolts (1).
24. Front Wheel Hub Bolt (1) » Remove and DISCARD [4x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 14

25. Front Wheel Hub (1) » Remove
26. Front Brake Shield (2) » Remove
27. Front Wheel Hub Seal (3) » Remove and DISCARD [2x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 15

28. Front Lower Control Arm Bracket Bolt (1) » Remove
29. Front Lower Control Arm Brace (2) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 16

Note

Support the front stabilizer shaft.

30. Front Stabilizer Shaft Bolt (1) » Remove [4x]
31. Front Stabilizer Shaft Clamp (2) » Remove [2x]
32. Front Stabilizer Shaft Insulator (3) » Remove [2x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 17

33. Front Stabilizer Shaft Link Nut - Lower (1) @ Front Stabilizer Shaft » Remove [2x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 18

34. Front Stabilizer Shaft (1) » Remove

Note

Support the steering knuckle to prevent over-articulation of the front upper control arm ball joint.

35. Support the steering knuckle with a suitable jack stand.

Front Lower Control Arm Replacement (4WD with Z56) — figure 19

36. Front Shock Absorber Bolt (1) » Remove [2x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 20

37. Front Lower Control Arm Ball Stud Nut (1) » Remove

Front Lower Control Arm Replacement (4WD with Z56) — figure 21

38. Front Lower Control Arm (1) @ Steering Knuckle (2) » Release —  use CH-43631 Ball Joint Separator (3)

Front Lower Control Arm Replacement (4WD with Z56) — figure 22

39. Mark the relationship of the front lower control arm adjust cams (3) and the front lower control arm adjust bolts (4) to the frame pins using a grease pencil.
40. Front Lower Control Arm Nut (1) » Remove [2x]

Note

The front lower control arm adjust cam retainers (2) are for factory alignment purposes only and should NOT be reused.

41. If equipped, remove and DISCARD the 2 front lower control arm adjust cam retainers (2).
42. Front Lower Control Arm Adjust Cam (3) » Remove [2x]
43. Front Lower Control Arm Adjust Bolt (4) » Remove [2x]

Front Lower Control Arm Replacement (4WD with Z56) — figure 23

44. Front Lower Control Arm (1) » Remove Installation Procedure

45. Front Lower Control Arm (1) » Install

Front Lower Control Arm Replacement (4WD with Z56) — figure 24

2. Front Lower Control Arm Adjust Bolt (3) » Install [2x]
3. Front Lower Control Arm Adjust Cam (2) » Install [2x]
4. Align the marks made on the front lower control arm adjust cams (2) and the front lower control arm adjust bolts (3) to the frame pins.

Note

The final torque on the lower upper control arm nut (1) is to be applied during the front camber adjustment procedure.

5. Front Lower Control Arm Nut (1) » Install and hand tighten [2x]
6. Support the steering knuckle with a suitable jack stand.

Caution

Refer to Fastener Caution.

7. Front Lower Control Arm Ball Stud Nut (1) » Install and tighten — Fastener Specifications

8. Front Shock Absorber Bolt (1) » Install [2x] — Fastener Specifications

9. Remove the jack stand supporting the steering knuckle.

10. Front Stabilizer Shaft (1) » Install

11. Front Stabilizer Shaft Link Nut - Lower (1) @ Front Stabilizer Shaft » Install and tighten [2x] — Fastener Specifications

Note

The front stabilizer shaft insulator slit faces rearward.

Note

Support the front stabilizer shaft.

12. Front Stabilizer Shaft Insulator (3) » Install [2x]

13. Front Stabilizer Shaft Clamp (2) » Install [2x]

14. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 14.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 14.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 14.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 14.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

15. Front Stabilizer Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

16. Front Lower Control Arm Brace (2) » Install

17. Front Lower Control Arm Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

18. Clean any debris and corrosion from the steering knuckle bearing pilot bore.

19. Apply a thin coating of grease evenly ensuring complete coverage of the steering knuckle pilot bore only. Adhesives, Fluids, Lubricants, and Sealers

Note

Ensure that the front wheel hub seals are properly seated in the grooves of the steering knuckle.

20. Front Wheel Hub Seal (3) » Install NEW [2x]

21. Front Brake Shield (2) » Install

22. Front Wheel Hub (1) » Install

23. Reposition the front wheel drive half shaft as necessary to install the front wheel hub bolts (1).

24. Front Wheel Hub Bolt (1) » Install and tighten the NEW bolt. [4x] — Fastener Specifications

25. Steering Linkage Outer Tie Rod Nut (1) » Install and tighten — Fastener Specifications

26. Front Wheel Speed Sensor Wiring Harness (1) » Install

27. Front Wheel Speed Sensor Bolt (2) » Install and tighten — Fastener Specifications

Note

Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminates should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

28. Using the CH-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.

29. Using the CH-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.

30. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure there are no foreign particles or debris remaining.

31. Front Brake Rotor (2) » Install

32. Front Brake Rotor Bolt (1) » Install and tighten — Fastener Specifications

33. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 33.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 33.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 33.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 33.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

34. Front Brake Caliper (1) » Install

35. Front Brake Caliper Bolt (2) » Install and tighten [2x] — Fastener Specifications

36. Front Brake Hose Bracket Bolt (1) » Install and tighten — Fastener Specifications

37. { If equipped } Position the front disc brake pad wear sensor wiring harness (1) into place.

38. { If equipped } Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper » Install

39. Have an assistant apply the brakes.

Caution

This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

40. Front Wheel Drive Shaft Nut (1) » Install NEW and tighten — Fastener Specifications

Note

The proper position of the underbody skid shield is between the underbody splash shield and the front frame.

41. {With RC1} Install the underbody skid shield: 41.1. Underbody Skid Shield (3) » Install 41.2. Underbody Splash Shield Bolt (2) » Install and tighten [2x] — Fastener Specifications 41.3. Underbody Skid Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

42. {Without RC1} Install the underbody skid shield: 42.1. Underbody Skid Shield (2) » Install 42.2. Underbody Skid Shield Bolt (1) » Install and tighten [4x] — Fastener Specifications

43. Install the front tire and wheel assembly. Tire and Wheel Removal and Installation

44. Remove the support and lower the vehicle.

45. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

46. Measure and adjust the wheel alignment. Front Caster and Camber Adjustment