How to Remove & Replace Rear Struts on a 2004 Chevy Cavalier

The rear suspension on the 2004 Chevy Cavalier was designed as a strut system. The strut system works much like a normal shock, only the coil spring is compressed between the strut and the upper strut mount. If the coil springs also need to be replaced, it is possible to purchase a whole strut assembly that includes a new coil spring and upper strut mount already assembled and ready to install into the vehicle.

Instructions

Removal

1

Place wheel chocks around the front wheels. Loosen the lug nuts on both rear wheels with the lug wrench.

2

Lift the vehicle into the air with the floor jack and place the jack stands under the rear suspension crossmember. Lower the floor jack until the vehicle rests securely on the jack stands. Shake the vehicle to ensure the vehicle is seated properly and is safe to work under.

3

Remove the lug nuts from both rear wheels with the lug wrench. Remove the rear wheels and tires from the vehicle.

4

Open the vehicle trunk and locate the upper strut mounting area on both sides next to the wheel wells. Place the floor jack under the strut and raise the jack just enough to support the strut from moving. Remove the nut closest to the center part of the vehicle.

5

Remove the two strut to body bolts located at the top of the strut in the inner wheel well with the socket and ratchet.

6

Remove the lower strut mounting bolt and nut with the socket and ratchet, using a wrench to counter the movement of the nut during removal. Hold the strut with one hand and lower the floor jack. Remove the strut from the vehicle.

Strut Tear Down and Build

7

Secure the strut assembly into the vice on the work bench. Set the spring compressors onto the coil spring 180 degrees apart from each other. Compress the spring by turning the compressor bolt one turn each until the spring is compressed enough to move around freely on the strut assembly.

8

Remove the dust cap from on top of the strut. Remove the strut piston rod nut with a wrench; use a wrench on the machined area of the rod to prevent counter movement. Remove the upper strut mount. Remove the coil spring. Remove the spring bumper. Lower the spring seat (if removable). Remove the old strut from the vice and discard.

9

Install the new strut into the vice and secure it by tightening the vice. Install the lower spring seat (if not part of the new strut). Slide the spring bumper over the strut piston rod until it rests on the spring seat. Set to compressed coil spring onto the strut. Install the dust seat onto the strut piston rod. Install the strut mount.

10

Thread the new strut piston rod nut onto the strut rod. Tighten the strut rod piston nut to 63 foot-pounds or torque. Fill the upper strut mount area with grease and install the dust cap.

11

Slowly loosen the spring compressors one turn at a time each until the spring is fully released and the spring compressors can be removed. Remove the strut assembly from the vice.

Installation

12

Set the new strut into position and align the strut to body stud with the inner most hole and push it up toward the floor. Set the strut over the lower suspension arm and install the lower mounting nut and bolt. Tighten to 51 foot-pounds of torque.

13

Install the two strut to body bolts through the inner wheel well and tighten to 18 foot-pounds with the torque wrench. Install the nut on the shock to body stud through the trunk and tighten to 18 foot-pounds with the torque wrench.

14

Place the wheels and tires onto the vehicle and install the lug nuts hand tight. Lift the vehicle off of the jack stands with the floor jack and remove the jack stands from under the vehicle. Lower the vehicle to the ground. Tighten the lug nuts in a crisscross pattern to 100 foot-pounds of torque with the torque wrench. Shut the vehicle's trunk.