This procedure covers the replacement of the front upper control arm bushings on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, requiring removal of the upper control arm for bushing replacement or pressing.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (left or right side) × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is still on ground (do not remove)
4. Raise front of vehicle with floor jack and support on jack stands at frame rail locations
5. Remove front wheel on side being serviced
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
7. Take photos of control arm orientation and mounting positions for reference during reassembly

Procedure

1. 1

   Remove upper ball joint cotter pin
   Locate the upper ball joint where it connects to the steering knuckle. Straighten and remove the cotter pin from the ball joint castle nut using a punch or cotter pin removal tool. Discard the old cotter pin as a new one will be installed during reassembly.
2. 2

   Loosen upper ball joint nut
   Using an 18mm socket, loosen the upper ball joint castle nut but do not remove it completely. Leave the nut threaded on 2-3 turns to protect the threads and prevent sudden separation when using the separator tool.
3. 3

   Separate ball joint from knuckle
   Position a ball joint separator or pickle fork between the upper control arm and steering knuckle at the ball joint taper. Strike the tool firmly with a hammer or tighten the separator tool until the ball joint taper releases from the knuckle. Once separated, remove the castle nut completely and carefully lower the knuckle away from the control arm.
   ⚠Ball joint may release suddenly. Keep hands and face clear of the separation point.
4. 4

   Support control arm
   Place a floor jack or jack stand under the lower control arm to support the weight of the suspension and relieve tension on the upper control arm. Raise just enough to take the load off the upper control arm bolts while keeping the assembly stable.
5. 5

   Remove control arm frame bolts
   Locate the two bolts securing the upper control arm to the frame rail brackets (front and rear positions). Using a 21mm socket, remove both control arm mounting bolts completely. Note the orientation and any alignment shims or washers present for reinstallation.
   ⚠Ensure control arm is supported before removing bolts to prevent sudden movement or dropping.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove upper control arm
   Carefully maneuver the upper control arm out of the frame brackets and remove it from the vehicle. It may be necessary to adjust the position of the lower control arm support or turn the steering to provide clearance. Inspect the ball joint and control arm for additional wear or damage while removed.
7. 7

   Press out old bushings
   Mount the control arm in a hydraulic press or arbor press. Using the appropriate size bushing removal tool from your bushing tool set, press the old bushings out of the control arm. Apply steady, even pressure and ensure the control arm is properly supported to prevent bending. Remove any remaining bushing material or corrosion from the control arm bores using a wire brush.
   ⚠Ensure control arm is properly aligned and supported in press to prevent damage to the arm or injury from slipping.
8. 8

   Install new bushings
   Clean the control arm bushing bores thoroughly with a wire brush and wipe clean. Apply a light coat of dish soap or bushing installation lubricant (not grease) to the new bushing outer sleeve. Position the new bushing at the bore opening, ensuring correct orientation if bushings are directional. Using the appropriate bushing installation tool and press, apply steady pressure to press the new bushing into the control arm bore until it is fully seated and flush with the control arm housing.
9. 9

   Install control arm to frame
   Position the control arm back into the frame rail brackets, aligning the bushing holes with the frame mounting points. Install both front and rear control arm bolts finger-tight only at this stage. Reinstall any alignment shims or washers in their original positions. Do not torque the bolts yet as they must be torqued with vehicle weight on the suspension.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
10. 10

    Connect ball joint to knuckle
    Raise the steering knuckle to align the upper ball joint stud with the knuckle bore. Insert the ball joint stud through the knuckle and thread the castle nut onto the stud. Tighten the castle nut to the specified torque of 101 Nm (75 lb-ft). If the castle nut slots do not align with the cotter pin hole, tighten the nut further (do not loosen) until alignment is achieved, not exceeding an additional 1/6 turn.
    Torque spec

    Ball Joint Nut101 Nm (75 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 in opposite directions around the castle nut to secure it properly. Ensure the cotter pin is fully seated and cannot back out.
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel back onto the hub and install all lug nuts. Tighten lug nuts in a star pattern by hand until snug. Remove jack stands and carefully lower the vehicle to the ground so full vehicle weight is resting on the wheels. This step is critical before final torquing of control arm bolts.
13. 13

    Torque control arm bolts with weight on suspension
    With the vehicle on the ground and suspension at normal ride height, use a 21mm socket and torque wrench to tighten both control arm frame bolts to the specified torque of 165 Nm (122 lb-ft). This ensures the bushings are properly positioned under load and prevents premature bushing failure.
    ℹ️This step must be performed with full vehicle weight on suspension. Torquing with suspension unloaded will cause premature bushing wear.
    Torque spec

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

    Final torque wheel lug nuts
    Using a torque wrench and 19mm socket, tighten all wheel lug nuts to the specified torque of 156 Nm (115 lb-ft) in a star pattern to ensure even pressure distribution.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Reassembly is covered in the main procedure steps
2. Ensure all fasteners are tightened to specification
3. Verify new cotter pin is properly installed and secured

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the front suspension
• Check for smooth steering operation without binding or unusual resistance
• Visually inspect all fasteners to confirm proper installation and torque
• Schedule a front-end alignment within 50 miles of completing this repair, as control arm removal affects alignment settings
• After 50-100 miles, re-check control arm bolt torque to ensure bolts have not loosened

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