I'll be installing Total Chaos upper control arms this weekend. I've watched the instructional install video from TC, read write-ups, and read the written instructions from TC. I've come across some misleading information and could use this forum's help to clarify my questions below.

1. Instructions call for greasing the inside of the bushing and the outside of the sleeve when assembling the UCA. Do I need to grease the bushings via the zerk fittings during initial install or is that a maintenance item later down the road?
2. More on grease - to avoid any premature squeaks/creaking noises, should I apply grease between the bushings and the washers?
3. Should the UCA through-bolt be tightened with the vehicle on the ground or up in the air?

https://www.youtube.com/user/ChaosFabrication/videos

before I installed I brushed grease everywhere (except the uniball) and before I tightened I used my grease gun thru the zerk and then tightened.
I tightened the thru bolt while lifted while the wheels were off. I dont think there is a wrong or right way.
I used Dry lube for the uniball.

hope this all helps and good luck with your install!

Don't overgrease the bushings as you'll find that the bushings will mushroom. I had to replace a few of mine because the excess grease tends to deform them. Add grease, cycle them a few times, if you see a little bit of extra come out, stop, and cycle them a few more times till it stops.

Only tighten the thru bolt when the wheels are on the ground. If you tighten it with the vehicle in the air and then lower it, you can deform the bushings.

Likewise, when you add grease via the zerk fittings, you are supposed to loosen off the thru bolt, add grease, and then tighten/torque the thru bolt, otherwise the bushings will bulge and you will no longer have a flat surface against the washers. This will lead to premature wear.
Grease will come out between the bushing and washer while you are tightening the bolt again.

a 19mm gear wrench really helps when loosening off the thru bolt for routine maintenance. Otherwise you will have to remove a bracket on the frame to fit a socket.

https://www.youtube.com/watch?v=xvMdAX2uybs

edit: to answer your questions:

1. yes, add grease before tightening the bolt. don't get carried away.
2. use a thin bit of grease on the surface of the bushing while you are greasing the sleeve. But grease will end up between the bushings and washers when you do number 1.
3. tighten with the vehicle on the ground

Thanks everyone! Looks like I'll need to find a grease gun before Saturday