How To Replace Front Control Arm 95-05 Pontiac Sunfire

Difficulty: Advanced · About 90 min · Pontiac Sunfire

Replace a front control arm on a 1995–2005 Pontiac Sunfire while supporting the suspension and protecting the ABS sensor wiring during removal.

Steps

1. Prepare and remove the wheel

   Apply penetrant to the control-arm fasteners, loosen the lug nuts, then raise and support the vehicle. Remove the wheel and keep the ABS wiring clear of the work area.

2. Disconnect the arm joints

   Unclip the ABS lead and remove the stabilizer link hardware. Take out the ball-joint cotter pin and nut, separate the joint from the knuckle, and remove both control-arm pivot bolts.

3. Remove the old control arm

   Support the strut or knuckle so it cannot drop or strain a hose. Work the control arm out of its mounts, using a pry tool carefully without damaging the subframe or nearby wiring.

4. Install the replacement arm

   Guide the replacement arm into the mounts and reconnect the ball joint to the steering knuckle. Start its pivot bolts by hand and raise the arm as needed to align the holes.

5. Secure the joints and wiring

   Tighten the ball joint and pivot fasteners to the vehicle's specification, installing a new cotter pin where required. Refit the stabilizer link and route the ABS wire in its original clips.

6. Reinstall the wheel and finish

   Refit the wheel and hand-start the lug nuts. Lower the car, tighten the wheel nuts in a star pattern to specification, then have the alignment checked before normal driving.

Check your vehicle’s repair manual for exact specifications and fit.