2022 Ford Bronco Rear End Tear Down -- Crawl Series Suspension Prep

Stripping the rear suspension on a 2022 Ford Bronco Wild Track to make room for Crawl Series control arms, a new panhard bar, and Falcon 3.5 inch coilovers in method bronze.

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Before you can install a lift kit on a 2022 Ford Bronco, everything in the rear has to come off first. This is the teardown episode of the Core 4x4 Bronco build series — removing the factory coilovers, all four control arms, and the panhard bar so we can replace them with Crawl Series parts powder coated in method bronze. The passenger side adds an extra step most tutorials skip: dropping the gas tank to reach the upper control arm bolt that Ford sandwiched between the tank and the frame.

Vehicle: 2022 Ford Bronco Wild Track (Eruption Green) | Goal: Strip the rear suspension for a 3.5 inch lift using Falcon coilovers and Core 4x4 Crawl Series arms

What Is Getting Replaced

Spence and Marissa from Core 4x4 standing in front of the Eruption Green 2022 Ford Bronco in the shop

This Bronco build is going from the Wild Track’s factory 1-inch lift to a full 3.5 inches — an additional 2.5 inches of suspension travel. To get there, every rear suspension component needs to come off and be replaced:

Rear coilovers — factory units out, Falcon 3.5 inch coilovers in
All four rear control arms — uppers and lowers replaced with Core 4x4 Crawl Series arms (Johnny Joints at both ends)
Panhard bar (track bar) — replaced with an adjustable Core 4x4 unit to recenter the axle at the new ride height
Icon billet aluminum upper control arms — for the front end (prepped and powder coated in this episode, installed in the next)

All of the Core 4x4 parts and the Icon upper arms are being powder coated in method bronze to match the Method wheels going on this rig. The eruption green body with bronze suspension components and bronze wheels is the look Eric (the owner) had in mind for this build.

Prep and Powder Coating

Disassembling Icon billet aluminum upper control arm on the workbench before powder coating

Before any teardown starts, the new parts need to be prepped for powder coat. The Icon billet aluminum upper control arms get disassembled — Johnny Joints, snap rings, and hardware come out so the bare arm can go into the powder coating booth. The same goes for the Crawl Series lower and upper control arms and the panhard bar.

Powder coating Bronco suspension components in the Core 4x4 paint booth

Core 4x4 does all powder coating in-house at their Orem, Utah facility. For this build, everything goes in method bronze — a warm metallic finish that complements the Eruption Green exterior. Powder coat is more durable than paint for suspension components because it resists chipping, scratching, and corrosion from trail debris and road salt.

Driver Side Rear Tear Down

Spence pointing at factory rear suspension components on the 2022 Ford Bronco up on the lift

With the Bronco on the lift and wheels off, the driver side comes apart first. The rear suspension on a 2022 Bronco has a coilover, an upper control arm, a lower control arm, and a panhard bar. Here is the teardown sequence for the driver side:

Remove the inner fender liner. This is critical for accessing the top hat of the coilover. Without it out, you cannot reach the rear-most bolt on the upper coilover mount.
Unbolt the coilover. There are three bolts at the top. A ratcheting 15mm wrench is the tool of choice because the space is extremely tight, especially for that back bolt.
Remove the lower control arm. Straightforward bolt removal on the driver side — no obstructions.
Remove the upper control arm. Also accessible on the driver side without dropping the gas tank.
Disconnect the panhard bar. One side comes off with the driver-side work.

The driver side is the easy side. Every bolt is accessible once the fender liner is out. The passenger side is where it gets complicated.

Passenger Side: Why You Have to Drop the Gas Tank

Rear suspension tear down in progress showing factory coilover and control arms on the 2022 Ford Bronco

On the passenger side of the 2022 Bronco, the upper control arm bolt is completely sandwiched between the gas tank and the frame rail. There is no way to get a wrench on it without lowering the tank. You could potentially reach the lower control arm by removing the skid plate shield, but the upper arm is a non-negotiable gas tank drop.

This is the most time-consuming part of the entire Bronco rear teardown, and it is the step that catches most DIYers off guard. Plan for it.

How to Drop the 2022 Bronco Gas Tank

Removing inner fender liner to access coilover top mount bolts on the 2022 Ford Bronco

Ford designed the Bronco fuel system with a built-in slack plate in the fuel lines, which means you do not have to disconnect the main fuel lines to lower the tank far enough for access. Here is what needs to come off:

Filler hose — disconnect this from the tank
Two wiring harnesses — one in the middle of the tank and one at the rear
Tank mounting hardware — remove the straps holding the tank to the frame

The Transmission Jack Method

Trevor working underneath the Bronco to lower the gas tank using a transmission jack for access to the upper control arm bolt

A transmission jack makes this job significantly easier. Support the tank on the jack, remove the straps, and then tilt the tank rearward and down rather than pulling it straight down. Tilting avoids putting stress on the front fuel lines that remain connected.

You only need to lower the tank enough to get a wrench on the upper control arm bolt — it does not have to come all the way out. Once the bolt is accessible, remove the upper and lower control arms on the passenger side and button up the tank.

Pro tip: Have a second person for the gas tank drop. Even with a transmission jack, a full gas tank is heavy and awkward. Spence brought Trevor over specifically for this step. If you are working alone, consider draining or siphoning the tank first to reduce the weight.

What Comes Off the Rear End

By the end of this teardown, the following factory components are removed from the rear:

Component	Quantity	Notes
Rear coilovers	2	Fender liner removal required to access top hat bolts
Upper control arms	2	Passenger side requires gas tank drop
Lower control arms	2	Driver side straightforward; passenger side may need shield removal
Panhard bar (track bar)	1	Accessible from driver side

New Parts: Crawl Series in Method Bronze

Freshly powder coated method bronze Icon billet aluminum upper control arm ready for assembly

With the rear end stripped, the replacement parts are ready. Everything coming out of the powder coating booth is finished in method bronze:

Core 4x4 Crawl Series rear control arms — Johnny Joints at both ends for maximum articulation and durability. The independent crush sleeves mean they can be torqued at any suspension position.
Core 4x4 adjustable panhard bar — essential when adding 2.5 inches of lift to keep the rear axle centered in the wheel wells.
Icon billet aluminum upper control arms — adjustable UCAs for the front end, prepped and ready for the next episode.
Falcon 3.5 inch coilovers — arriving next week; the rear install will continue once these are in hand.

The Crawl Series is Core 4x4’s top-tier line. Every arm has Johnny Joints at both ends instead of polyurethane bushings, which gives you full articulation without binding and eliminates the need to torque at ride height. For a Bronco that is going to see trail use on 37-inch tires, Crawl is the right choice.

Shop Bronco Crawl Series Suspension Kit

Tools Required for Bronco Rear Tear Down

Lift or jack stands (vehicle needs to be high enough to work underneath comfortably)
Ratcheting 15mm wrench (critical for coilover top-hat bolts)
Standard socket set (metric)
Transmission jack (for gas tank drop)
Penetrating fluid (PB Blaster or equivalent)
Trim removal tools (for fender liners)
Second person (recommended for the gas tank step)

Tips for a Smoother Bronco Rear Tear Down

Start with the driver side. It is easier and lets you get a feel for the bolt locations and clearances before tackling the passenger side.
Remove both fender liners early. You need them out for coilover access on both sides, and it only takes a few minutes.
Do not skip the transmission jack. Trying to hold the gas tank by hand while lowering it is dangerous and unnecessary. The jack lets you tilt it precisely without pulling on fuel lines.
Budget extra time for the passenger side. The gas tank drop adds 30–45 minutes to the job depending on your experience level.
Label everything. The Bronco has multiple similar-looking brackets and hardware. Photos or labeled bags save time during reassembly.

What Comes Next in the Bronco Build

With the rear end stripped, the next step is assembling and installing the Crawl Series control arms, the adjustable panhard bar, and the Falcon 3.5 inch coilovers once they arrive. The front end also gets the Icon billet upper control arms and front coilovers. The build finishes with 37-inch tires on Method wheels in bronze.

This is Part 1 of the Core 4x4 Ford Bronco build series. Stay tuned for the rear suspension install and the front end build in upcoming installments.

Frequently Asked Questions

Yes — on the passenger side, the upper control arm bolt is sandwiched between the gas tank and the frame. There is no way to access it without lowering the tank. The driver side does not require a gas tank drop. Ford built in slack in the fuel lines, so you only need to disconnect the filler hose and two wiring harnesses to lower the tank far enough for access.

A transmission jack is strongly recommended. It supports the weight of the tank and lets you tilt it rearward instead of pulling straight down, which avoids stressing the front fuel lines. You will also need a socket set to remove the tank straps and a helper to guide the tank as it lowers.

Crawl Series arms have Johnny Joints at both ends for maximum articulation and the ability to torque at any suspension position. Camp Series arms use a polyurethane bushing on one end and a Johnny Joint on the other. For a Bronco build with 37-inch tires and trail use, Crawl Series is the recommended choice for durability and flex.

The top hat of the rear coilover on the 2022 Ford Bronco is tucked behind the inner fender liner. There are three bolts at the top, and the rear-most bolt is impossible to reach without the liner removed. A ratcheting 15mm wrench is the best tool for the tight space even with the liner out.

With a lift and a transmission jack, expect roughly 2 to 3 hours for the complete rear teardown. The driver side takes about 30 to 45 minutes. The passenger side with the gas tank drop adds another hour or more depending on experience. Having a second person for the gas tank step saves significant time.