Lower control arm - front bolt doesn't fit

[NBinSD]

I'm mounting my steel LCAs from my 2003 sedan donor. The manual says to re-use the factory mounting hardware for the front bolt, but the bolt on my LCAs won't fit through the mounting hole in the frame. It gets through the threads but not the smooth collar of the bolt. Anyone else have this issue? Just drill the hole a bit bigger?

I'm pretty confident I have the correct bolts there, but I searched but didn't seem to find anyone else with this issue.

[Hindsight]

If I recall correctly, I had to take a round file to those holes. Basically just had to knock the thick powder coat off the inside of the holes and the bolt went through.

[Bob_n_Cincy]

If I recall correctly, I had to take a round file to those holes. Basically just had to knock the thick powder coat off the inside of the holes and the bolt went through.
I totally agree,
I have 2 coats of powder on mine and I had to drill out almost every suspension mount hole.
10mm 12mm 14mm 16mm and 1/2"
You want the suspension holes very tight with no clearance if possible.
Bob

[billjr212]

Same - I took a small round file for a few laps around these and didn't have a problem after that (and a light "tap" with a rubber mallet).

[Frank818]

I used the same bolts as your coming of a steel arm (but used on alu arms on the 818) and I had no real problem fitting them, I might have tapped on them with something, but that's all. The powder coat is your problem. I also painted my bolt which makes it thicker and more prone to not fit, but yours is not painted.

[mrprgrmr]

If I remember correctly, I drilled out the holes for the same reason. I also had issues with there being a bit of twisting/tension on the LCA bushings, even after I figured out that I had the aluminum bushing housings upside down. I initially thought those were symmetrical so it wouldn't matter. The LCA wouldn't swing up and down freely (this is prior to torqueing the bolts); a relatively small amount of filing of the front holes eased up most of the tension on the bushings. I am using a wagon donor with slightly differing mounting points. YMMV, etc

[svanlare]

I had to do the same, a quick file and tap them in with a hammer.

[suttonb3]

I just ran into this last week. I was so excited to finally be bolting parts on, my heart sank when I saw the bolts wouldn't fit. I just knew that when I disassembled my donor 6 months ago that I had somehow mixed them up. I remember cursing my name and thinking about how my goal of a 1 year build will need to be modified to 5 or 6, but it turned out that a gentle tap of a hammer was all that was needed to overcome the thick powder coating.

[Hindsight]

FYI there are only a couple diamters of bolts used on the donor for suspension. If you have thecwrong bolt, it REALLY wont fit.

[NBinSD]

Picked up a round file at lunch today and I'll knock some of the powder coating off tonight and give it another shot. Suttonb I'm with you... first subaru part I'm bolting on and it didn't fit!

[Bob_n_Cincy]

Picked up a round file at lunch today and I'll knock some of the powder coating off tonight and give it another shot. Suttonb I'm with you... first subaru part I'm bolting on and it didn't fit!

Welcome to the party. By the end of the project we will change you middle name to MacGyver.

[AZPete]

Amazing. Ten replies to the question . . . and they all agree! Usually there are several better ways to solve a problem and a few that involve essential new tools or expensive upgrades. This site is amazing, as usual.

[NBinSD]

Knocking the powder coat off with the file worked great and I was able to get both LCAs mounted. Moved onto threading the ball joint into the upper control arm... very tight fit, one went on after freezing the ball joint, the other was much more problematic. I brushed the coating off the threads of the ball joint and am leaving it in the freezer overnight.

[Bob_n_Cincy]

Knocking the powder coat off with the file worked great and I was able to get both LCAs mounted. Moved onto threading the ball joint into the upper control arm... very tight fit, one went on after freezing the ball joint, the other was much more problematic. I brushed the coating off the threads of the ball joint and am leaving it in the freezer overnight.

MacGyver,
Don't be afraid to also warm up the A-arm socket with a propane torch. I also had problems here.
Put the ball joint in a big vice, And use the a-arms to rotate it around. I used a cheater bar over the long threaded end on the socket bracket.
Don't forget that the long thread goes toward the front of the car.
Bob