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Wanderlust
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4,158 Posts
Discussion Starter · #1 · (Edited)
I helped mbisson with the installation of the Total Chaos Upper Control Arms on his FJ Cruiser and thought it may be useful to post the steps we used today.

Installing Total Chaos Upper Control Arms (UCA) on a FJ Cruiser

Removing factory UCAs (ref.: FSM 02600410):

1. Choke rear tires
2. Lift vehicle and place jackstand under frame
3. Remove wheel and tire
4. Support front Lower Control Arm (A arm)
5. Retain spindle with wire or rope to prevent spindle from falling away when upper ball joint is removed
6. Remove bolt holding ABS wire bracket; remove wire from bracket (bracket is not re-used)
7. Remove cotter pin and remove nut holding the upper ball joint to the spindle (Exercise care since nut is fairly soft and may be rounded easily)
8. Use ball joint separator to detach upper ball joint from spindle (a pickle fork may also be used)
9. Loosen nut on UCA pivot bolt
10. On driver’s side, loosen battery and place wedge under battery and detach wiring harness from bracket next to battery; on passenger’s side detach AC line from plastic bracket to make room for the pivot bolt removal
11. Remove pivot bolt and the two washers

Remove balljoint from spindle using a balljoint separator


Installing Total Chaos UCAs
:

1. Thread pivot bolt through washer, front UCA arm, washer, UCA mount on frame, washer, rear UCA arm, washer (make sure ABS wire is outside of UCA)
2. Install nut onto pivot bolt and torque to 85 ft-lb
3. Insert adaptor onto spindle
4. Insert bolt through upper misalignment spacer, uniball, lower misalignment spacer, spindle adaptor, washer
5. Install nut and torque nut to 100 ft-lb
6. Zip-tie ABS wire onto rear of TC UCA
7. Grease polyurethane bushings at zerk fittings with synthetic grease such as Redline CV-2 or SuperLube
8. Spray Tri-Flow teflon lubricant onto uniball
9. Cycle UCA to make sure there’s no interference and there is slack in ABS wire
10. Install wheel and torque wheel nuts to 85 ft-lb
11. Lower vehicle
12. Repeat on the other side
13. Inspect and adjust front alignment

Total Chaos UCA installed shown at full droop


edit: added link to Total Chaos instruction

Total Chaos UCA PN 96504 instruction
 

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Registered
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472 Posts
Yeah, I have been a lucky bastid, but what I need now is a lift! I am still trying to make up my mind.
 

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173 Posts
very nice writeup, i especially liked the post for the use a proper ball joint separator and not a "hammer" like all pro says. a note on the one bolt TC provides though, the TC spindle bolt needs a 13/16 inch socket, but the provided nut is a sensible metric 22mm
 

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Premium Member
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714 Posts
Thong glad you helped Mike finally get them installed! Great write-up!
So am I. We did knock them out in a hurry. It is a lot easier with two people though. One can put in the long bolt while the second lines up the washers and UCA. Thong really knows what he is doing. I want to publicly thank him for his help. I know I would have been very frustrated trying to do this by myself.
 

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Premium Member
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3,985 Posts
great write-up Thong.

so, maybe you can help me with my UCA install when (if) i get them? :D
 

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Wanderlust
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4,158 Posts
Discussion Starter · #12 ·
So am I. We did knock them out in a hurry. It is a lot easier with two people though. One can put in the long bolt while the second lines up the washers and UCA. Thong really knows what he is doing. I want to publicly thank him for his help. I know I would have been very frustrated trying to do this by myself.
Anytime Mike.

great write-up Thong.

so, maybe you can help me with my UCA install when (if) i get them? :D
Let me know. :)
 

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Premium Member
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897 Posts
thanks for the writeup! this should help me when i install my Camburg UCAs in a few weeks.
 

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Wanderlust
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4,158 Posts
Discussion Starter · #14 ·
I forgot to mention that spraying the balljoint threads with Liquid Wrench or something similar would help in loosening the nuts. Also, there is not a whole lot of room between the pivot nut and the body, so a 19mm crowfoot wrench is handy for torquing down the nuts.
 

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3,329 Posts
One other thing on torque. Don't use an impact wrench and assume that getting them tight will work. They need to be torqued to spec or you'll damage the bushings.
 

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6,956 Posts
Anyone else have eyes bigger than their wallet? I am suffering from this syndrome in a big way these days...

*sigh*

I went to Total Chaos' website as a result of this thread... it only made it worse! They have stuff for my old pickup too!
 

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3,361 Posts
Anyone else have eyes bigger than their wallet? I am suffering from this syndrome in a big way these days...

*sigh*

I went to Total Chaos' website as a result of this thread... it only made it worse! They have stuff for my old pickup too!
Im right there with you man, I want and want and want.......just need some money damnit.
 
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