Front suspenion A-arm refurm, Step-by-step Options

[racunniff]

My car had the most annoying popping / grinding sound coming from the passenger's side front A-arm. It got to the point that I almost did not want to drive the car any more. So, I decided to do something about it. Once I had diagnosed that it was the A-arm bearings causing the sound, I went to the Pelican and ordered this part (part number 99-3014-340-M230):



You'll need the following tools:

1. Sockets - 11mm, 13mm, 17mm, 19mm
2. Allen wrench - 8mm
3. A BFH - "Big Friendly Hammer"
4. Rubber mallet
5. Breaker bar, pry bars, chisels, heat source, etc.
6. Some grease (I used some white lithium grease)

I jacked the car up, and removed the wheel, so I could access the suspension:



Here is what the A-arm looked like at the begnining of this whole process:



First step in removing the A-arm is to remove the torsion bar adjusting screw (using an 11mm socket) and then pry the adjusting arm off the torsion bar (I used an Allen wrench as a lever to push it from behind):



Next is to remove the tapered pin from the ball joint. You back the nut off so it's clear of the threads (using a 13mm socket) and then you *carefully* strike it with a hammer - here is my BFH about to strike the nut (which has been soaking for a bit in penetrating oil). You have to hit it pretty hard to loosen it, but eventually, it will pop forward:



Once you get the initial "pop" you'll need to remove the nut and then use another bolt or something as a drift to push the pin far enough out so you can get at it with vice grips or something.

Coming soon, Part II

[racunniff]

Part V


And now, for the whole point of this exercise - installing the bushings. There are two different bushings in the bag - a front bushing (with "2557" stamped on it):



...and a rear bushing (with "2558" stamped on it):



I put the front bushing on first. I lightly greased the A-arm bearing surface with some lithium grease, and then pushed the bushing on. I then lightly greased the front mounting point and pushed it on over the bushing. The front went on pretty easily (make sure that the "washer"-like reinforcements are facing the correct direction, which is "up" relative to the installed position of the arm):



The rear was, well, a pain in the rear. It was a much tighter fit - appropriate, I guess, given than it was much harder to remove. You can use the old rear bushing as a drift and a rubber mallet to push the bushing on (after lightly greasing again). And then you put the front mounting point on (don't forget the grease) - and here, you pretty much have to use a BFH again. You can invert the old bushing, putting the wide part of the shoulder against the mounting point, and strike it with the hammer until it is well in place (make sure the bolt hole is on the correct side of the A-arm):



And here it all is, all shiny and pretty and ready to reinstall:



Coming soon, Part VI