This procedure covers the removal and replacement of the rear control arm bushings on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, requiring removal of the control arm from the vehicle.

Warnings

Tools required

Parts

• Rear control arm bushing set (inner and outer) × 1 — Use OEM specification or equivalent
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground, but do not remove
4. Raise rear of vehicle and support securely on jack stands under the frame rails
5. Remove rear wheel on the side being serviced
6. Apply penetrating oil to ball joint nut, control arm bolts, and any rusted fasteners. Allow to soak for 15-20 minutes

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle/hub assembly to support it and maintain suspension geometry. Raise the jack just enough to take light pressure off the control arm, but do not lift the vehicle off the jack stands.
2. 2

   Remove the ball joint cotter pin
   Locate the ball joint connection at the knuckle. Straighten and remove the cotter pin from the ball joint castle nut using needle-nose pliers. Discard the old cotter pin.
3. 3

   Remove the ball joint nut
   Using an 18mm socket, remove the ball joint castle nut from the ball joint stud. Keep this nut as it will be reused.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
4. 4

   Separate the ball joint from the knuckle
   Using a ball joint separator or pickle fork, separate the control arm ball joint from the rear knuckle. Insert the separator between the control arm and knuckle, then strike or apply pressure according to the tool type. Once separated, lower the floor jack slightly to allow the control arm to drop down and create working clearance.
   ⚠Control the separation carefully to prevent the knuckle from dropping suddenly. Maintain support with the floor jack.
5. 5

   Remove the front control arm bolt
   Locate the front control arm mounting bolt at the frame bracket. Using a 21mm socket and breaker bar, remove the bolt and nut. Note the orientation and any washers or spacers for reinstallation. The bolt may require significant force to break loose.
   Torque spec

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

   Remove the rear control arm bolt
   Locate the rear control arm mounting bolt at the axle housing. Using a 21mm socket and breaker bar, remove the bolt and nut. Note the orientation and any washers or spacers for reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove the control arm from vehicle
   Once both mounting bolts are removed, carefully maneuver the control arm out of the vehicle. It may be necessary to rotate or angle the arm to clear the axle housing and frame components. Inspect the ball joint for wear while the arm is removed.
8. 8

   Remove the old bushings
   Using a hydraulic press or bushing removal tool kit, press out the old bushings from the control arm. Support the control arm properly in the press, ensuring the bushing has clearance to exit completely. Note the orientation of the bushings before removal, particularly any offset or directional features.
   ⚠Ensure the control arm is properly supported in the press to prevent damage or injury. Wear safety glasses as old bushings may fracture during removal.
9. 9

   Clean the bushing bores
   Thoroughly clean the bushing bores in the control arm using a wire brush. Remove all rust, debris, and old bushing material. Inspect the bores for cracks or damage. Apply a thin film of clean grease to the bores to aid installation.
10. 10

    Install new bushings
    Using a hydraulic press or bushing installation tool kit, press the new bushings into the control arm. Ensure the bushings are oriented correctly, matching any offset or directional features noted during removal. Press the bushings in evenly until fully seated and flush with the control arm housing. Verify both bushings are seated completely.
    ⚠Misaligned bushings during installation can be damaged. Ensure the bushing and press tooling are properly aligned before applying pressure.
11. 11

    Install control arm to vehicle
    Position the control arm back into the vehicle, aligning the bushing holes with the mounting points at the frame and axle housing. Install the front and rear control arm bolts through the bushings and mounting brackets, threading the nuts on finger-tight only. Do not torque at this time.
12. 12

    Reconnect the ball joint to knuckle
    Raise the floor jack under the knuckle to align the ball joint stud with the hole in the knuckle. Once aligned, insert the ball joint stud through the knuckle. Install the ball joint castle nut and tighten to specification using an 18mm socket and torque wrench. Align the castle nut slots with the stud hole and install a new cotter pin. Bend the cotter pin ends to secure.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
13. 13

    Install wheel and lower vehicle to ground
    Install the rear wheel and thread the lug nuts on by hand. Tighten the lug nuts in a star pattern snug but not to final torque. Carefully lower the vehicle until the tire contacts the ground and the suspension is supporting the vehicle weight, but keep the jack stands in place as a safety backup.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
14. 14

    Torque control arm bolts with weight on suspension
    With the vehicle weight now on the suspension, torque the front and rear control arm bolts to specification using a 21mm socket and torque wrench. This is critical to ensure the bushings are in their natural position under load, preventing premature wear.
    ⚠Failure to torque control arm bolts with vehicle weight on suspension will cause rapid bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
15. 15

    Final torque wheel lug nuts and remove jack stands
    Torque the wheel lug nuts to final specification in a star pattern using a torque wrench. Once complete, fully lower the vehicle and remove the jack stands. Torque the lug nuts once more in a star pattern to verify proper seating.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. If servicing both sides, repeat the entire procedure for the opposite rear control arm
2. Verify all fasteners are torqued to specification
3. Confirm the new cotter pin is properly installed and secured on the ball joint

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the rear suspension
• Check for proper rear wheel alignment and steering feel
• After 50-100 miles of driving, re-check the torque on the control arm bolts and wheel lug nuts
• Inspect the ball joint cotter pin to ensure it remains secure
• Schedule a professional alignment check to ensure proper rear suspension geometry

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