Replace the upper control arm on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including removal of the ball joint and reinstallation with proper torque specifications.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or equivalent aftermarket
• Ball joint castle nut × 1 — Included with control arm or purchase separately
• Cotter pin × 1 — Standard automotive cotter pin

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Lift front of vehicle and support securely on jack stands under frame rails
4. Remove wheel and tire assembly
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
6. Inspect upper control arm and ball joint for wear, cracks, or damage

Procedure

1. 1

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut. Using a 21mm socket, remove the castle nut securing the upper ball joint to the steering knuckle. Do not discard the nut yet in case you need to use it to press the ball joint taper out.
2. 2

   Separate ball joint from knuckle
   Insert a ball joint separator or pickle fork between the upper control arm and steering knuckle. Strike firmly with a hammer to break the taper fit. Alternatively, thread the castle nut back on a few turns and strike the knuckle boss with a hammer while applying upward pressure on the control arm. Once separated, remove the castle nut completely.
   ⚠Ball joint may separate suddenly. Support the knuckle assembly to prevent it from dropping.
3. 3

   Support lower control arm
   Position a floor jack under the lower control arm to support the weight of the suspension and prevent the knuckle from dropping when the upper control arm is removed. Raise jack just enough to support, not to lift the vehicle.
4. 4

   Remove upper control arm mounting bolts
   Locate the two bolts securing the upper control arm to the frame. These are at the inner mounting points with horizontal orientation. Using an 18mm socket and wrench, remove both front and rear upper control arm mounting bolts. Note the orientation of any washers or spacers for reinstallation.
   ℹ️The rear bolt may be difficult to access. A universal joint or wobble extension may be helpful.
5. 5

   Remove upper control arm
   Once both mounting bolts are removed, pull the upper control arm away from the frame and maneuver it out of the wheel well. The ball joint stud should already be separated from the knuckle. Remove the assembly completely from the vehicle.
6. 6

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting surfaces where the upper control arm bolts attach. Remove any rust, dirt, or debris. Clean the ball joint taper seat on the steering knuckle as well to ensure proper fit of the new ball joint.
7. 7

   Install new upper control arm
   Position the new upper control arm into the frame mounts. Insert both front and rear mounting bolts through the frame and control arm bushings. Thread bolts in by hand but do not torque yet. The bolts must be torqued with vehicle weight on the wheels.
8. 8

   Connect ball joint to knuckle
   Align the upper ball joint stud with the hole in the steering knuckle. You may need to use the floor jack under the lower control arm to raise or lower the knuckle for alignment. Insert the ball joint stud through the knuckle and thread on the new castle nut.
   Torque spec

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

   Torque ball joint nut
   Using a torque wrench and 21mm socket, torque the ball joint castle nut to 101 Nm (75 lb-ft). If the cotter pin holes do not align, tighten the nut slightly more until the next castle slot aligns with the hole. Never loosen the nut to align the cotter pin hole. Install a new cotter pin and bend the ends to secure.
   ⚠Always advance the nut to the next castle slot if needed. Never back off the nut to align the cotter pin hole.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
10. 10

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread all lug nuts on by hand, then snug them in a star pattern but do not torque yet. Remove the jack stands and carefully lower the vehicle until the tires contact the ground but the suspension is not fully loaded. The vehicle should be at normal ride height with weight on the wheels.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
11. 11

    Torque control arm bolts at ride height
    With the vehicle at normal ride height and weight on the wheels, torque both upper control arm mounting bolts to 165 Nm (122 lb-ft). This is critical - torquing these bolts while the suspension is hanging will cause premature bushing failure. Use an 18mm socket and torque wrench.
    ⚠Control arm bolts MUST be torqued at ride height with vehicle weight on wheels. Failure to do so will cause bushing binding and premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
12. 12

    Torque wheel lug nuts
    Fully lower the vehicle to the ground. Using a torque wrench, torque the wheel lug nuts to 156 Nm (115 lb-ft) 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 bent in ball joint castle nut
3. Check that no tools or parts were left in the wheel well

Verification

• Bounce the front suspension several times to settle the components
• Visually inspect that the upper control arm is properly seated in frame mounts
• Verify the ball joint castle nut has a properly installed cotter pin
• Test drive the vehicle at low speed and verify no unusual noises or handling issues
• Schedule a professional alignment - replacing the upper control arm will affect camber and caster settings

More procedures for this vehicle