This procedure covers the removal and replacement of the rear upper control arm on a 2011-2014 Ford F-150 4WD with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Rear upper control arm assembly × 1 — Use OEM specification or equivalent
• Ball joint castle nut (if not reusable) × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support securely with jack stands under frame rails
5. Remove rear wheel on side being serviced
6. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support rear knuckle assembly
   Position a floor jack under the rear knuckle/axle assembly to support its weight. Raise jack until it just contacts the assembly but does not lift the vehicle. This prevents the suspension from dropping when the upper control arm is disconnected.
2. 2

   Remove ball joint cotter pin and nut
   Locate the upper control arm ball joint where it connects to the knuckle. Remove the cotter pin from the castle nut. Using a 15mm socket, remove the ball joint castle nut completely. Keep the nut if it is in good condition, otherwise replace.
3. 3

   Separate ball joint from knuckle
   Install a ball joint separator tool between the upper control arm and knuckle. Tighten or strike the separator according to tool design to break the taper connection. Once separated, support the control arm to prevent it from falling. The knuckle will drop slightly onto the floor jack.
   ⚠Ball joint may release suddenly. Ensure jack is supporting knuckle weight and keep hands clear.
4. 4

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame bracket. Using an 18mm socket and wrench, remove the bolt and nut. The bolt passes through a bushing in the control arm. Note the orientation of any washers or spacers for reinstallation.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the frame bracket. Using an 18mm socket and wrench, remove the bolt and nut. Support the control arm as you remove the final fastener, then remove the control arm from the vehicle.
6. 6

   Inspect mounting points and clean
   Inspect the frame mounting brackets for damage, cracks, or excessive rust. Use a wire brush to clean the bolt holes and mounting surfaces. Check the knuckle ball joint taper seat for damage or deformation. Clean any corrosion or debris from all mounting surfaces.
7. 7

   Install new upper control arm
   Position the new control arm into the frame brackets. Insert both front and rear mounting bolts through the bushings and frame brackets, but do not tighten fully yet. Thread nuts onto bolts finger-tight only. The control arm should move freely on the bolts at this stage.
8. 8

   Connect ball joint to knuckle
   Align the ball joint stud with the hole in the knuckle. You may need to raise or lower the floor jack slightly to align the components. Once aligned, install the castle nut onto the ball joint stud and tighten to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the pin ends to secure.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
9. 9

   Lower vehicle to load suspension
   Remove jack stands and carefully lower the vehicle until the full weight is on the wheels, but keep the floor jack partially supporting the vehicle for safety. The suspension must be at normal ride height with vehicle weight on the wheels before torquing control arm bolts. Do not allow vehicle to rest on the floor yet.
10. 10

    Torque control arm mounting bolts
    With vehicle weight on the suspension, torque both the front and rear control arm mounting bolts to specification using an 18mm socket and torque wrench. This is critical to prevent bushing bind. Torque both bolts while the suspension is loaded.
    ⚠Control arm bolts must be torqued with vehicle weight on suspension. Failure to do so will cause premature bushing failure.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Raise vehicle slightly and remove the floor jack from under the knuckle. Install the rear wheel and thread lug nuts by hand. Lower the vehicle completely to the ground. Torque the lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Verify cotter pin is properly installed and bent in ball joint castle nut
3. Remove all tools and equipment from under vehicle

Verification

• Test drive vehicle at low speed and listen for unusual noises from rear suspension
• Verify no clunking or looseness when driving over bumps
• Schedule a professional wheel alignment as soon as possible, as suspension geometry has been altered
• After 50-100 miles, re-check torque on all fasteners

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