Service Procedure
INSTRUCTIONS FOR INSTALLATION OF THE REINFORCEMENT KITNOTE:
Disregard instructions enclosed in kit # 15624685. Use procedures "Initial Position of Reinforcement" and "Reinforcement Installation" listed.
PRELIMINARY INSPECTION OF THE CONTROL ARM
1. Raise the left front of the vehicle and support it with suitable safety stands.
2. Inspect the left hand lower control arm to determine if the subject vehicle requires modification. Arms subject to kit installation will have a small radius of 0.1 inch (2.54 mm) at the flange-to-nose transition (Figure 1), instead of the intended 1.0 inch (25.4 mm) nominal radius (Figure 2). All right hand lower control arms have the proper radius and may be used for comparison.
NOTICE:
Some 85/86 vehicles may have had their lower control arms replaced. If inspection of the left lower control arm indicates the 1.0 inch (25.4 mm) nominal radius shown in Figure 2, the control arm will NOT require a reinforcement kit. Submit a Product Campaign claim for INSPECT CONTROL ARM no action required.
INITIAL POSITIONING OF THE REINFORCEMENT
1. Clean the left hand lower control arm of all dirt, rust, grease, and undercoating from the spring pocket outboard. Clean both the top and bottom areas of the control arm. This will insure good mechanical contact of the reinforcement and U-bolt to the control arm and ball joint flange. Use appropriate solvents and/or a wire brush as required.
NOTICE:
If the control arm and the reinforcement are not thoroughly cleaned, the U-bolt may "walk" off the bottom of the bag joint when it is tightened.
2. Center the reinforcement (Figure 3B "1") between the flanges. Gaps A & B (Figure 3B) are to be equal within 0.060 inch (1.5 mm). Secure the reinforcement with a "C" clamp.
Important
The reinforcement is installed CORRECTLY when the ball joint makes full contact with the reinforcement radius (Figure 3B), not just in the center section of the reinforcement.
The reinforcement is designed to fit ball joints with a bottom diameter of 2.60 inches (66 mm) or greater. The technician may find that the ball joint does not make full contact with the radius of the reinforcement when the reinforcement is centered between the flanges (Step 2 "INITIAL POSITIONING OF REINFORCEMENT").
It is possible that an aftermarket ball joint with a bottom diameter which is less than 2.60 inches (66 mm) has been installed. This does not allow for full contact with the radius of the reinforcement. When this happens, only a small section of the ball joint will be centered on the reinforcement. If this occurs, make certain the ball joint is clean as described in step 1. Then measure the bottom diameter of the ball joint with calipers. If the measurement is LESS THAN 2.6 inches (66 mm), the ball joint must be replaced with a Genuine GM ball joint.
3. Install the U-bolt (Figure 3, "7") and torque it to approximately 10 N-m (7 lbs.ft.).
Important
THIS STEP MUST BE PERFORMED BEFORE PROCEEDING TO STEP 4.
NOTICE:
When correctly installed, the U-bolt, will be about even with bottom of the ball joint. The U-bolt is NOT designed to fit into the galley of the control arm. On some vehicles the U-bolt may contact the flange edge of the control arm and interfere with the correct installation. In these cases you may remove only enough material (LIGHTLY grind) (Figure 3A) from the outer radius of the U-bolt to allow clearance between the U-bolt and the control arm (Figure 3, "7") .
4. Drill a center hole with a 3/8 inch (9.5 mm) drill. The reinforcement (Figure 3, "1") has been designed to be used as a drill guide. When drilling, keep the drill as perpendicular as possible.
5. Install a 3/8-16 bolt (Figure 3, "6"), nut (Figure 3, "3") and washer (Figure 3, "2") in the center hole and torque them to approximately 18 N-m (13 lbs.ft).
6. Remove the "C" clamp.
7. Drill the three remaining holes in any sequence.
8. Disassemble the reinforcement (Figure 3, "1") and U-bolt (Figure 3, "7") from the control arm and remove all of the chips or burrs from the reinforcement.
INSTALLATION OF THE REINFORCEMENT
1. Reinstall the reinforcement (Figure 4, "1") and U-bolt (Figure 4, "7"). Hand start all of the bolts. Tighten the U-bolt nuts (Figure 4, "5") to approximately 22 N-m. (16 lbs.ft.). Make sure the U-bolt is ALIGNED with the bottom edge of the ball joint and is NOT COCKED while continuing to torque.
NOTICE:
If the rear most bolt head flange interferes with the bump stop bracket, install the bolt from the bottom of the control arm.
2. Torque the 3/8-16 bolts (Figure 4, "6") to 37 - 43 N-m. (27 - 32 lbs.ft.). Tighten the center bolt first and the remainder in any sequence.
3. Torque the U-bolt nuts (Figure 4, "5") to 40 - 46 N-m. (30 - 34 lbs.ft.).
4. Lower the vehicle.
5. Install "Campaign Identification Label."