Control Arm Replacement – 2.5L NA

Overview

This procedure outlines the steps to replace the front control arm on all Porsche 944 variants with an 8-valve engine, covering both pre-1985.5 (83-85.5) models with steel control arms and 1985.5 onwards (86-88) models with aluminum control arms. The control arm connects the front suspension to the chassis and is critical for maintaining proper wheel alignment and handling. Replacing a worn control arm addresses issues like knocking sounds, excessive play, or damaged ball joint boots, ensuring safe and smooth operation.

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Tools Required

• Metric socket set (including 13mm, 17mm, 19mm sockets)
• Metric wrench set (including 13mm (1/2 inch), 17mm (11/16 inch), 19mm (3/4 inch) wrenches)
• Torque wrench (capable of 23 Nm to 100 Nm (17 ft-lbs to 74 ft-lbs))
• Rubber hammer
• Jack and jack stands
• Block of wood (for jack pad)
• Brightly colored marker (e.g., nail polish) for alignment marking

Parts Required

• Control arm (steel for pre-85.5: 944 341 027 01; aluminum for 85.5 onwards: 944 341 027 03)
• Lock nuts for control arm bolts: 999 084 052 02 (multiple required)
• Eccentric bolt bushing (if replacing): 944 341 243 01
• Ball joint boot (if replacing torn boot on pre-85.5): 944 341 925 00

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Place the vehicle on jack stands to securely elevate the front end.
2. Remove the front wheels using a 19mm (3/4 inch) socket.
3. Remove the skid pans (underbody panels) using a 10mm (3/8 inch) socket to access the suspension components.

Step 2: Remove the Sway Bar

4. Disconnect the front sway bar from the body by removing the M8 bolts using a 13mm (1/2 inch) socket.
5. Disconnect the sway bar from the control arm using a 13mm (1/2 inch) socket and remove the sway bar from the vehicle.

Step 3: Mark and Disconnect the Control Arm (Pre-85.5 and 85.5 Onwards)

6. Mark the orientation of the eccentric bolt (rear of the control arm) to the control arm using a brightly colored marker (e.g., nail polish) to ensure proper alignment during reassembly.
7. Remove the nut and bolt attaching the spindle to the ball joint using a 19mm (3/4 inch) wrench and socket.
8. If replacing the rear eccentric bolt bushing, remove the lock nut at the rear of the eccentric bolt using a 19mm (3/4 inch) wrench.
9. Remove the front lock nut on the eccentric bolt using a 19mm (3/4 inch) wrench.
10. Remove the two bolts attaching the eccentric bolt bushing to the body using a 13mm (1/2 inch) socket.
11. Remove the bolt and nut attaching the front of the control arm to the cross-member using a 17mm (11/16 inch) wrench and socket.

Step 4: Remove the Control Arm

12. Using a rubber hammer, tap the top of the control arm near the ball joint to free it from the spindle.
13. Remove the control arm from the vehicle.

Step 5: Prepare the New Control Arm (Pre-85.5 and 85.5 Onwards)

14. If the eccentric bolt assembly was removed, transfer the eccentric bolt orientation mark from the old control arm to the new control arm.
15. Attach the eccentric bolt to the new control arm, aligning it with the transferred mark.
16. Torque the eccentric bolt lock nut to 100 Nm (74 ft-lbs) using a torque wrench.

Step 6: Install the New Control Arm

17. Position the new control arm in the vehicle and install the control arm to cross-member bolt using a 17mm (11/16 inch) wrench and socket, but do not fully tighten yet.
18. Slide the eccentric bushing onto the eccentric bolt and bolt it to the body with two bolts using a 13mm (1/2 inch) socket. Loosely install the rear eccentric lock nut using a 19mm (3/4 inch) wrench.
19. Fit the ball joint shaft into the spindle assembly, ensuring it is fully inserted.
20. Install the ball joint to spindle bolt and lock nut using a 19mm (3/4 inch) wrench and socket. Torque to 50 Nm (37 ft-lbs).

Step 7: Torque Suspension Components

21. Place a jack under the ball joint with a block of wood on the jack pad. Raise the jack until it just supports the vehicle’s weight to simulate normal suspension load.
22. Torque the control arm to cross-member bolt to 65 Nm (48 ft-lbs) using a torque wrench.
23. Torque the eccentric bolt assembly to body bolts to 46 Nm (34 ft-lbs) using a torque wrench.

Step 8: Reinstall the Sway Bar (Pre-85.5 and 85.5 Onwards)

24. Reattach the front sway bar to the body using M8 bolts and torque to 23 Nm (17 ft-lbs) with a 13mm (1/2 inch) socket.
25. (Pre-85.5) For steel control arms, reattach the sway bar to the control arm and torque the bolts to 23 Nm (17 ft-lbs) using a 13mm (1/2 inch) socket.
26. (85.5 Onwards) For aluminum control arms, reattach the sway bar to the control arm and torque the bolts to 25 Nm (18 ft-lbs) using a 13mm (1/2 inch) socket.

Step 9: Final Reassembly

27. Remove the jack from under the ball joint.
28. Reinstall the front wheels using a 19mm (3/4 inch) socket and torque to 130 Nm (96 ft-lbs).
29. Reinstall the skid pans using a 10mm (3/8 inch) socket.

Post Procedure Checklist

• Verify all bolts are torqued to the specified values (50 Nm (37 ft-lbs) for ball joint, 65 Nm (48 ft-lbs) for cross-member, 46 Nm (34 ft-lbs) for eccentric assembly, 23-25 Nm (17-18 ft-lbs) for sway bar).
• Check for any play in the control arm by pushing up near the ball joint; there should be no noticeable movement.
• Test drive the vehicle for 5 miles (8 km) and listen for knocking or unusual noises from the front suspension.
• Inspect the alignment marks on the eccentric bolt to ensure they remain aligned.
• Schedule a professional wheel alignment to ensure proper suspension geometry.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube