This procedure covers removal and replacement of the front lower control arm bushings on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, requiring separation of the ball joint and removal of the control arm.

Warnings

Tools required

Parts

• Front lower control arm bushing kit × 2 — Use OEM specification or Moog K200869
• Cotter pin × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands placed on frame rails
5. Remove front wheels completely
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove cotter pin and loosen ball joint nut
   Locate the lower ball joint nut at the bottom of the steering knuckle. Remove the cotter pin using pliers or a cotter pin remover. Using a 21mm socket, loosen the ball joint nut but do not remove it completely yet. Leave it threaded on 2-3 turns to protect the threads during separation.
2. 2

   Separate ball joint from knuckle
   Position a ball joint separator tool between the lower control arm and the steering knuckle at the ball joint taper. Strike the separator firmly with a hammer or tighten the screw-type separator until the ball joint releases from the knuckle taper. Once separated, remove the ball joint nut completely. Support the knuckle assembly to prevent it from hanging on the brake hose or CV axle.
   ⚠The ball joint will release suddenly. Ensure the knuckle is supported and keep hands clear of pinch points.
3. 3

   Disconnect sway bar link (if necessary)
   If the sway bar link interferes with control arm removal, disconnect it from the lower control arm. Hold the link shaft with an Allen key (typically 6mm) and remove the nut using an 18mm socket. Allow the link to hang from the sway bar.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
4. 4

   Mark control arm position and remove mounting bolts
   Before removal, mark the position of the control arm relative to the frame mounting points using a paint marker or scribe. This helps with alignment during reinstallation. Using a 21mm socket and breaker bar, remove the front and rear control arm mounting bolts. Support the control arm as you remove the final bolt, as it will drop free.
   ⚠Control arm is heavy and may drop suddenly when final bolt is removed. Keep hands and feet clear.
5. 5

   Remove control arm from vehicle
   Lower the control arm and remove it from the vehicle. Maneuver it carefully around the CV axle, brake components, and frame. Place the control arm on a stable work surface for bushing removal.
6. 6

   Press out old bushings
   Clean the control arm bushing bores with a wire brush. Using a hydraulic press with appropriately sized adapters or a bushing removal tool, press out the old bushings from the control arm. The bushings are press-fit and will require significant force. Ensure the control arm is properly supported in the press to avoid damage. Press from the inside out to avoid damaging the bore.
   ⚠Use proper press adapters that contact only the bushing, not the control arm bore. Misalignment can damage the arm.
7. 7

   Clean bushing bores and inspect control arm
   Thoroughly clean the bushing bores in the control arm using a wire brush and solvent. Remove all rust, debris, and old rubber. Inspect the control arm for cracks, bends, or damage. Check the ball joint for excessive play or torn boots. Replace the entire control arm if any damage is found.
8. 8

   Press in new bushings
   Apply a light coat of soapy water or bushing installation lubricant to the outside of the new bushings and the control arm bores. Align the bushing carefully with the bore, ensuring it is perfectly square. Using the hydraulic press with proper adapters, press the bushing straight into the bore until it is fully seated and flush with the control arm. The bushing orientation voids should align with the control arm mounting bolt axis. Repeat for all bushings.
   ⚠Bushings must be pressed in straight and square. Cocking will damage both bushing and control arm. Use proper size adapters.
9. 9

   Reinstall control arm to frame
   Position the control arm with new bushings back into the vehicle, maneuvering around the CV axle and suspension components. Align the control arm with the frame mounting points using your earlier reference marks. Insert both front and rear mounting bolts and thread them by hand. Do NOT torque these bolts yet - they must be torqued with vehicle weight on the suspension.
10. 10

    Reconnect ball joint to knuckle
    Raise the lower control arm using a floor jack to align the ball joint stud with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and install the ball joint nut. Tighten the nut to specification using a 21mm socket and torque wrench. Install a new cotter pin through the castellated nut and ball joint stud, bending the ends to secure.
    ℹ️If cotter pin holes do not align, tighten nut further until next slot aligns. Never loosen to align.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
11. 11

    Reconnect sway bar link
    If previously disconnected, reconnect the sway bar end link to the lower control arm. Hold the link shaft with an Allen key and tighten the nut to specification using an 18mm socket and torque wrench.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Reinstall wheels and lower vehicle
    Reinstall the front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle carefully from the jack stands until the full weight of the vehicle is resting on the suspension, but keep the jack stands in place as a safety backup.
13. 13

    Torque control arm bolts with vehicle weight on suspension
    With the vehicle weight fully on the suspension (wheels on ground or on stands at normal ride height), torque the front and rear control arm mounting bolts to specification using a 21mm socket and torque wrench. This is critical - torquing these bolts with the suspension hanging will cause premature bushing failure.
    ⚠Control arm bolts MUST be torqued at normal ride height with vehicle weight on suspension. This is critical for bushing longevity.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final torque wheel lug nuts
    Remove jack stands completely and lower vehicle fully to the ground. Torque all wheel lug nuts to specification in a star pattern using a 19mm socket and torque wrench.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both control arm bushings
2. Double-check that all fasteners are tightened to specification
3. Verify new cotter pins are properly installed and bent
4. Ensure no tools or parts were left in the wheel well or under the vehicle

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the front suspension
• Check for proper steering response and no pulling to either side
• Perform a visual inspection under the vehicle to confirm no fluid leaks and all fasteners are secure
• Schedule a professional front-end alignment within 50 miles of completion, as control arm removal affects alignment settings

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