Here's a general outline of the process:
1. Preparation:
* Safety First: Disconnect the negative battery terminal. Use jack stands to securely support the vehicle after lifting it. Wear safety glasses and gloves.
* Gather Tools: You'll need a jack, jack stands, wheel chocks, socket set (metric), wrenches (metric), a ball joint separator (or pickle fork – use with caution!), a bushing press (or strong C-clamp and appropriate sockets/adapters), penetrating oil (PB Blaster or similar), a hammer, and possibly a torque wrench. New bushings and possibly new bolts are essential.
* Consult a Repair Manual: A factory service manual or a reputable repair guide specific to your 2004 Chevy Malibu is crucial. It will provide detailed diagrams, torque specifications, and crucial removal/installation sequences.
2. Removal:
* Remove the Wheel: Remove the wheel on the side you're working on.
* Disconnect Brake Caliper: Carefully unbolt and support the brake caliper (tie it up to something secure to prevent it from hanging by the brake line).
* Disconnect Sway Bar Link: Disconnect the sway bar link from the trailing arm.
* Disconnect ABS Sensor (if applicable): Carefully disconnect the ABS sensor wire from the trailing arm.
* Remove Trailing Arm Bolts: This is where it gets tricky. The trailing arm is likely bolted to the chassis. Use penetrating oil liberally on the bolts well in advance. You'll likely need to loosen and remove these bolts. The exact number and location will be detailed in your repair manual.
* Remove Trailing Arm: Once the bolts are removed, you might need to use a ball joint separator to gently separate the trailing arm from the control arm. Be careful not to damage the components. The trailing arm may now be removed from the vehicle.
3. Bushing Removal and Installation:
* Bushings Out: This is where a press is ideally needed. You might be able to use a C-clamp and sockets to carefully press the old bushings out, but this requires patience and precision to avoid damaging the trailing arm.
* Clean: Thoroughly clean the trailing arm and the bushing bore.
* Bushings In: Use a press to install the new bushings. Ensure they are seated correctly and evenly. Again, using a C-clamp is possible but challenging and risky. Improper installation will lead to premature failure.
4. Reassembly:
* Install Trailing Arm: Carefully reinstall the trailing arm, ensuring all bolts are properly tightened to the specifications in your repair manual.
* Reconnect Components: Reconnect the sway bar link, ABS sensor (if applicable), and brake caliper. Make sure everything is connected securely.
* Torque Specifications: Use a torque wrench to tighten all bolts to the manufacturer's specified torque settings. This is critical to prevent premature wear or failure.
* Reinstall Wheel: Reinstall the wheel and tighten the lug nuts properly.
* Lower Vehicle: Carefully lower the vehicle to the ground.
* Test Drive: Perform a test drive to ensure everything is working correctly.
Important Considerations:
* Press is Recommended: Using a press is highly recommended for removing and installing the bushings. Improper techniques can easily damage the trailing arm.
* Torque Specifications: Always adhere to the manufacturer's torque specifications. Over-tightening can damage threads or components, while under-tightening can lead to loosening and failure.
* Professional Help: If you're uncomfortable performing this repair, take your vehicle to a qualified mechanic. Improper installation can lead to serious safety hazards.
This is a simplified overview. Refer to a repair manual specific to your 2004 Chevy Malibu for detailed instructions and torque specifications. Safety is paramount; if you are unsure about any step, seek professional assistance.
