This procedure covers the removal and replacement of the upper ball joint on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD. The job requires separating the ball joint from the knuckle and removing the upper control arm.

Warnings

Tools required

Parts

• Upper ball joint × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Pinch bolt (if applicable) × 1 — Use new bolt per torque spec

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support with jack stands under frame rails
4. Remove wheel and tire assembly
5. Spray all ball joint and control arm fasteners with penetrating oil and allow to soak

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the suspension. Raise slightly to compress the suspension approximately 1 inch. This will relieve tension on the upper ball joint and prevent the knuckle from dropping when disconnected.
2. 2

   Remove sway bar link if needed
   If sway bar link interferes with upper control arm access, remove the upper sway bar link nut. Hold the shaft with an Allen key to prevent rotation while removing the nut. Set aside for reinstallation.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint castle nut at the top of the steering knuckle. Use pliers to straighten and remove the cotter pin. Discard the old cotter pin. Remove the castle nut using an 18mm or 21mm socket (verify size on your specific application). Do not fully remove the nut yet - leave it threaded on a few turns to protect threads.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint taper from the steering knuckle. Position the separator between the control arm and knuckle, then strike or tighten to break the taper free. Once separated, remove the castle nut completely. Support the knuckle to prevent it from falling.
   ⚠The knuckle may drop suddenly when ball joint separates. Ensure floor jack is supporting the lower control arm and be prepared to control knuckle movement.
5. 5

   Remove upper control arm mounting bolts
   Locate the two upper control arm mounting bolts at the frame. These bolts secure the control arm to the frame brackets. Use a 15mm or 18mm socket with breaker bar to remove both bolts. Support the control arm as you remove the second bolt to prevent it from falling.
6. 6

   Remove upper control arm
   With both mounting bolts removed, carefully lower and remove the upper control arm from the vehicle. Inspect the control arm bushings for wear or damage while removed. Place the control arm on a clean work surface for ball joint removal.
7. 7

   Press out old ball joint
   Using a ball joint press kit, position the control arm in the press with the receiving cup below the ball joint and the forcing screw above. Apply steady pressure to press the old ball joint out of the control arm. The ball joint is press-fit and will require significant force. Clean the ball joint bore in the control arm with a wire brush after removal.
   ⚠Ensure press components are properly aligned before applying pressure. Misalignment can damage the control arm.
8. 8

   Press in new ball joint
   Position the new ball joint in the control arm bore with the stud facing the correct direction (compare to old ball joint orientation). Using the ball joint press, apply steady even pressure to press the new ball joint into place until fully seated. The ball joint should be flush with the control arm surface or seated to manufacturer specifications.
9. 9

   Install upper control arm
   Position the upper control arm back into the frame mounting brackets. Insert both control arm bolts and thread them in by hand. Do NOT fully torque these bolts yet - they must be torqued with vehicle weight on the suspension. Tighten snug enough to hold position only.
10. 10

    Connect ball joint to knuckle
    Guide the upper ball joint stud into the hole in the top of the steering knuckle. You may need to use a pry bar to align the knuckle or adjust the floor jack height under the lower control arm. Install the castle nut and tighten to specification. Ensure the castle nut slots align with the cotter pin hole in the stud. If not aligned, tighten further (never loosen) until the next slot aligns.
    Torque spec

    Ball Joint Nut117 Nm (86 lb-ft)
11. 11

    Install new cotter pin
    Insert a new cotter pin through the castle nut slots and ball joint stud hole. Bend the cotter pin ends outward to secure it in place. Ensure the cotter pin is properly seated and cannot back out.
12. 12

    Reinstall sway bar link if removed
    If the sway bar link was removed, reconnect it to the upper control arm or frame mounting point. Hold the shaft with an Allen key and tighten the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
13. 13

    Install wheel and lower vehicle
    Reinstall the wheel and tire assembly. Thread lug nuts by hand, then tighten in a star pattern. Lower the vehicle until the tire just contacts the ground but suspension is not fully loaded. Remove jack stands and lower vehicle completely to the ground.
14. 14

    Final torque specifications
    With the vehicle on the ground and weight on the suspension, torque the wheel lug nuts to specification in a star pattern. Then torque the upper control arm mounting bolts to specification. This must be done with the suspension at normal ride height to prevent binding of the control arm bushings.
    ℹ️Torquing control arm bolts with suspension unloaded will cause premature bushing failure and handling problems.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Torque all fasteners to specifications in the order listed
2. Verify cotter pin is properly installed and secured
3. Ensure ball joint moves freely without binding when steering is turned lock to lock

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering feel and no pulling to one side
• Schedule a front-end alignment as suspension geometry has been altered
• Re-check all torque specifications after 50-100 miles of driving
• Visually inspect ball joint boot for damage and proper seating

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