This procedure covers the removal and replacement of the front upper control arm bushings on a 2011-2014 Ford F-150 with the 5.0L V8 Coyote engine and 4WD, requiring removal of the control arm from the vehicle.

Warnings

Tools required

Parts

• Front upper control arm bushings (both sides) × 2 — Motorcraft or aftermarket equivalent
• Cotter pin for ball joint × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is 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. Spray all control arm fasteners with penetrating oil if corrosion is present

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection at the upper control arm. Use an Allen key to hold the ball stud shaft while removing the upper nut with a wrench. Disconnect the sway bar link from the control arm.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove upper ball joint cotter pin
   Locate the upper ball joint stud nut at the top of the steering knuckle. Straighten and remove the cotter pin using pliers or a cotter pin puller. Discard the old cotter pin.
3. 3

   Loosen ball joint nut
   Using a breaker bar and socket, loosen but do not fully remove the upper ball joint nut. Leave the nut threaded on a few turns to prevent the knuckle from dropping when the ball joint releases.
   ⚠Do not remove the nut completely until the ball joint taper is separated to prevent knuckle damage.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
4. 4

   Separate ball joint from knuckle
   Insert a ball joint separator tool between the upper control arm and steering knuckle. Apply pressure to break the taper fit of the ball joint stud. Once separated, support the knuckle assembly and remove the ball joint nut completely.
   ⚠The knuckle assembly will drop when the ball joint releases. Support it with your hand or a bungee cord.
5. 5

   Mark control arm position
   Before removing the control arm mounting bolts, mark or note the position of any shims or alignment cams present. Take a photo for reference during reassembly to maintain approximate alignment settings.
6. 6

   Remove control arm mounting bolts
   Locate the two mounting bolts that secure the upper control arm to the frame brackets. Using a breaker bar and socket, remove both front and rear control arm mounting bolts. Support the control arm as you remove the final bolt.
   ℹ️These bolts are extremely tight. A breaker bar or impact wrench may be necessary.
   Torque spec

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

   Remove control arm from vehicle
   Carefully lower and remove the upper control arm from the vehicle. Maneuver it out from between the frame and suspension components. Place on a clean work surface.
8. 8

   Press out old bushings
   Using a hydraulic press or bushing removal tool kit, press the old bushings out of the control arm. Apply even pressure and ensure the control arm is properly supported to prevent distortion. Remove both front and rear bushings.
   ⚠Ensure the control arm is properly supported in the press to avoid bending or distorting the arm.
9. 9

   Clean bushing bores
   Use a wire brush to thoroughly clean the bushing bores in the control arm. Remove all rust, dirt, and old bushing material. Inspect bores for damage or excessive wear. Apply a light film of clean oil to the bores.
10. 10

    Press in new bushings
    Position the new bushings in the control arm bores, ensuring correct orientation. Using a hydraulic press or bushing installation tool, press the new bushings into place until fully seated. Verify that bushings are centered and flush with the control arm mounting surfaces.
    ℹ️Some bushings have orientation marks or voids that must align with specific directions. Check manufacturer instructions.
11. 11

    Install control arm to frame
    Position the control arm back into the frame brackets, ensuring any shims or alignment cams are installed in their original positions as marked earlier. Insert both mounting bolts but do NOT torque them at this time. Thread them in just enough to hold the arm in place.
    ⚠Control arm bolts must NOT be torqued until vehicle weight is on the suspension to prevent bushing bind and premature failure.
12. 12

    Connect ball joint to knuckle
    Position the steering knuckle so the upper ball joint stud seats into the knuckle taper. Install the ball joint nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, then bend the ends to secure.
    ℹ️If the cotter pin hole does not align, tighten the nut slightly more (never loosen) until the next castle slot aligns with the hole.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
13. 13

    Reconnect sway bar link
    Connect the sway bar link to the upper control arm. Hold the ball stud shaft with an Allen key while installing and torquing the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
14. 14

    Install wheel and lower vehicle
    Install the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground but the suspension is at normal ride height with vehicle weight on the wheels. Do NOT lower completely onto the ground yet.
15. 15

    Torque control arm bolts with load
    With the vehicle weight on the suspension at normal ride height, torque both control arm mounting bolts to specification. This is critical to prevent bushing bind. After torquing, fully lower the vehicle to the ground.
    ⚠This step is critical. Torquing control arm bolts with suspension hanging will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
16. 16

    Torque wheel lug nuts
    With the vehicle fully on the ground, torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Repeat the entire procedure for the opposite side if replacing both upper control arm bushings
2. Control arm mounting bolts were torqued with vehicle weight on suspension in Step 15 as required

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the front suspension
• Check that steering response is normal with no pulling or wandering
• Verify the ball joint cotter pin is properly installed and secured
• Schedule a professional wheel alignment as control arm removal will affect alignment settings

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