This procedure covers the removal and replacement of the front lower lateral arm (control arm) on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD.

Warnings

Tools required

Parts

• Front lower lateral arm (control arm) × 1 — Use OEM specification or equivalent
• Ball joint castle nut × 1 — Replace if damaged
• Cotter pin for ball joint × 1 — Standard replacement item

Preparation

1. Park vehicle on level ground and set parking brake
2. Loosen front wheel lug nuts while vehicle is still on ground
3. Raise front of vehicle and support securely on jack stands at frame rails
4. Remove front wheel on the side being serviced
5. Apply penetrating oil to ball joint nut and control arm bolts, allow to soak 10-15 minutes
6. Support lower control arm with floor jack positioned near ball joint

Procedure

1. 1

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut. Using an 18mm socket, remove the ball joint castle nut from the lower ball joint stud where it connects to the steering knuckle. Keep the floor jack supporting the control arm to maintain suspension position.
2. 2

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the ball joint stud from the steering knuckle. Work carefully to avoid damaging the knuckle or brake components. Once separated, carefully lower the floor jack slightly to allow the control arm to drop away from the knuckle.
   ⚠The control arm may drop suddenly when the ball joint releases. Maintain control of the floor jack.
3. 3

   Remove front control arm bolt
   Locate the front control arm mounting bolt at the front subframe attachment point. Using an 18mm socket and wrench, remove the bolt and any washers. Note the orientation of washers and spacers for reinstallation. The bolt may be very tight and require a breaker bar.
4. 4

   Remove rear control arm bolt
   Locate the rear control arm mounting bolt at the rear subframe attachment point. Using an 18mm socket and wrench, remove the bolt and any washers. Again, note orientation of all components. Lower the floor jack and remove the control arm from the vehicle.
5. 5

   Inspect and clean mounting points
   Inspect the subframe mounting points for damage, corrosion, or worn bushings. Use a wire brush to clean the bolt holes and mounting surfaces. Inspect the ball joint taper in the steering knuckle for damage. Check the new control arm bushings for proper fitment before installation.
6. 6

   Install new control arm
   Position the new control arm into place, aligning the mounting holes with the subframe. Support with the floor jack if needed. Insert the front and rear control arm bolts with washers in their correct orientation, but do NOT torque them yet. Thread the bolts in by hand first to ensure proper alignment.
7. 7

   Connect ball joint to knuckle
   Raise the control arm using the floor jack until the ball joint stud aligns with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and install the new castle nut. Tighten the castle nut to specification, ensuring the cotter pin holes align. If necessary, tighten slightly more (never back off) to align the holes.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
8. 8

   Install cotter pin
   Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin to secure it properly, ensuring it cannot work loose. Trim excess length if necessary.
9. 9

   Reinstall wheel and lower vehicle
   Reinstall the wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground but the suspension is not yet fully loaded. Snug the lug nuts in a star pattern, then lower the vehicle completely so the full weight is on the wheels.
10. 10

    Torque control arm bolts with weight on suspension
    With the vehicle weight fully on the suspension (wheels on ground), torque the front and rear control arm bolts to specification. This is critical for proper bushing alignment and longevity. Use a torque wrench and 18mm socket.
    ⚠Control arm bolts MUST be torqued with vehicle weight on the suspension. Torquing them while suspended will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Torque wheel lug nuts
    Using a torque wrench and 21mm socket, torque the wheel lug nuts to specification in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify cotter pin is properly installed and secured
3. Double-check that control arm bolts were torqued with vehicle weight on suspension

Verification

• Test drive the vehicle and listen for unusual noises from the front suspension
• Verify steering feels normal with no binding or unusual feedback
• Check for proper wheel alignment; schedule alignment service if vehicle pulls to one side
• Re-torque wheel lug nuts after 50-100 miles of driving
• Visually inspect the control arm installation after test drive for any signs of improper installation

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