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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 734 (Front Suspension System) >> Repair Instructions >> Upper Ball Joint Replacement (RWD) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the vehicle.
    CAUTION: Floor jack must remain under the lower control arm during removal and installation to retain the lower control arm in position. Failure to do so could result in personal injury.
  2. Support the lower control arm with a safety stand.
  3. Remove the tire and wheel.
  4. Disconnect the wheel speed sensor connector from the upper control arm.
  5. Remove the cotter pin and the upper ball joint retaining nut.
    Fig 1: Cotter Pin & Upper Ball Joint Retaining Nut
    G02501634Courtesy of GENERAL MOTORS CORP.
  6. Separate the upper ball joint from the steering knuckle using J 23742  . Apply pressure on the tool until the stud breaks loose.
    7. Fig 2: Separating Upper Ball Joint From Steering Knuckle
    G02501635Courtesy of GENERAL MOTORS CORP.
  7. Remove J 23742  .
  8. Pull the steering knuckle free from the upper ball joint.
  9. Support the steering knuckle in order to prevent the steering knuckle weight from damaging the brake hose.
  10. Use a 3.175 mm (1/8 in) drill bit in order to cut 6.35 mm (1/4 in) deep holes in the center of each rivet head.
    Fig 3: Drilling Out Rivets
    G02501636Courtesy of GENERAL MOTORS CORP.
  11. Drill away the rivet heads using a 12.7 mm (1/2 in) drill bit.
  12. Using a small pin punch, punch out the rivets.
    13. Fig 4: Punching Out Rivets
    G02501638Courtesy of GENERAL MOTORS CORP.
  13. Remove the upper ball joint from the upper control arm.
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