Lower control arm problem.....

So here's the deal. I have a 2006 LT base model. I live on a dirt road and started noticing a horrible rattle. Both lower control arm bushings were toast....so I put all new control arms on both sides (and new struts and end links for the heck of it). I go on the test drive after I do the work and the driver side sounds good but I get the same rattle coming from the passenger side control arm bushing. I take the wheel back off and see that the control arm is quite cocked in the rear mount, causing the metal on metal rattle. This is a brand new control arm with bushing. There is no adjustment on this, so I was wondering if anyone had any advice? Anyone ever have the same problem?

Shitty. Picture?

No pic yet....is it possible I knocked out the bushing wrestling the control arm back in?

It's possible. I haven't replaced mine before.

Quick test for you. Jack one side up, and remove wheel. Place a 6x6 block of wood under lower control, by the ball joint with out hitting the rotor. Let jack down so vehicle is resting on the block of wood. KEEPING YOURSELF OUT FROM UNDER THE VEHICLE, use a large pry bar on the back of the control arm to see if you can get it to hit the sub frame, in both up and down motions. If you can get it to hit easily this may be your noise. I say maybe, because there are other things it could be. You can check both sides this way.

You said you replaced control arms, struts, sway bar links. You may have missed SWAY BAR bushings. Or left something you replaced loose. Were the struts, QUICK STRUTS? Meaning a whole new complete strut, with new springs and mount plate? Cobalts also have a steering shaft and sometimes a noise from the electric power assist motor.

Onedoughboy- I did use the quick struts. I have removed the problem control arm and can see metal to metal rubbing in the rear near the bushing where it mounts in the frame. It also looks more twisted in the mount than the driverside control arm. I don't understand as it is a brand new control arm and matches perfectly with the one I took out. Could I have a bent subframe or control arm mount? The mount LOOKS ok.

I suppose it could be a bad new part. You should return it, and compare it to another one while your in the store, unless you got it off the internet. The bushing can be driving in a little more, maybe even centered. It's just pressed in, couple of large sockets and a hammer will do the trick. You can bend the lower ear of the cradle, the upper is pretty much fixed. I punch the bushings in with a hammer all the time.

I might just buy a bushing and a ball joint and rebuild the old control arm. I the control arm I bought was a cheapie off Ebay (new). I don't have a socket quite big enough to press it in.

i've borrowed the kit that oreilly's has for ball joints, and i've used harbor freight bj kits. both worked out alright for my truck. i'm sure it'll work for cobalt's bjs too.

if you've got some random pipe laying around, you could build your own press with short sections & a c-clamp haha!