Replace the worn radius arm bushings on the front suspension to restore proper alignment and handling characteristics.

Warnings

Tools required

Parts

• Radius arm bushing kit (front, both bushings per arm) × 2 — Use OEM Ford specification or Moog K200791
• Cotter pins for ball joint × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheels completely
6. Spray all radius arm mounting bolts and ball joint nuts with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Remove wheel speed sensor (if equipped)
   Disconnect the wheel speed sensor electrical connector and carefully unclip the sensor wire from the radius arm and brake line brackets to prevent damage during radius arm removal. Store sensor wire out of the way.
2. 2

   Separate ball joint from knuckle
   Remove the cotter pin from the radius arm ball joint castle nut. Using a breaker bar and socket, loosen and remove the ball joint nut completely. Use a pickle fork or ball joint separator tool to separate the ball joint stud from the steering knuckle. Work carefully to avoid damaging the ball joint boot if reusing the radius arm.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
3. 3

   Support the radius arm
   Position a floor jack under the radius arm near the ball joint end to support its weight once the mounting bolts are removed. Raise jack just enough to take the weight but not to lift the vehicle.
4. 4

   Remove front radius arm mounting bolt
   Locate the large through-bolt at the front of the radius arm where it connects to the frame bracket. Using a breaker bar, remove the nut from the front mounting bolt. Drive the bolt out using a hammer and punch if necessary. The bushing will remain in the radius arm for now.
   ⚠The bolt may be seized in the bushing sleeve. Apply additional penetrating oil and use controlled force to avoid damaging the frame bracket.
5. 5

   Remove rear radius arm mounting bolt
   Locate the rear mounting bolt where the radius arm connects to the axle housing or lower control arm bracket. Remove the nut and bolt completely. Slowly lower the floor jack while guiding the radius arm down and forward to remove it from the vehicle. Note the orientation and any shims present.
6. 6

   Remove old bushings from radius arm
   Using a hydraulic press and appropriate press adapters, or a radius arm bushing removal tool kit, press out both the front and rear bushings from the radius arm. Work carefully to avoid damaging the radius arm eye. If bushings are severely deteriorated, they may need to be cut or burned out.
   ⚠Ensure press adapters support the arm properly to prevent bending or distortion of the radius arm during bushing removal.
7. 7

   Clean radius arm bushing bores
   Use a wire brush and cleaning solvent to thoroughly clean the inside of both bushing bores in the radius arm. Remove all rust, old rubber residue, and debris. Inspect the bores for damage, cracks, or excessive wear. Replace the radius arm if damage is found.
8. 8

   Install new bushings
   Apply a light coat of dish soap or bushing installation lubricant (not grease) to the outer surface of the new bushings and the inside of the radius arm bores. Using a hydraulic press or bushing installation tool, press the new bushings into the radius arm. Ensure bushings are oriented correctly per manufacturer instructions and are pressed in square and to the proper depth, typically flush with the arm surface.
   ℹ️Many radius arm bushings have a specific orientation with offset voids. Consult the bushing manufacturer diagram before pressing in.
9. 9

   Install radius arm to frame
   Position the radius arm back into the vehicle with the ball joint end toward the knuckle. Align the front bushing with the frame bracket and insert the front mounting bolt through the frame bracket and bushing. Thread the nut on by hand but do not torque yet. Support the arm with the floor jack.
10. 10

    Install rear mounting bolt
    Align the rear of the radius arm with the axle housing or lower control arm mounting bracket. Install any shims that were present during removal in their original positions. Insert the rear mounting bolt and thread the nut on by hand. Do not torque yet.
11. 11

    Connect ball joint to knuckle
    Raise the floor jack to lift the radius arm ball joint into the steering knuckle tapered hole. Install the ball joint castle nut and tighten to specification. The nut must be torqued properly and the cotter pin hole must align. If necessary, tighten the nut slightly more (never loosen) to align the cotter pin holes. Install a new cotter pin and bend tabs to secure.
    ⚠Never loosen the ball joint nut to align cotter pin holes. Only tighten further if needed for alignment.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
12. 12

    Reinstall wheel speed sensor
    Route the wheel speed sensor wire back through the original clips on the radius arm and brake line brackets. Reconnect the electrical connector. Ensure the wire has adequate slack and will not be pinched or stretched during suspension travel.
13. 13

    Install wheels and lower vehicle
    Install the front wheels and thread lug nuts by hand. Lower the vehicle until the tires just contact the ground but the suspension is not yet fully loaded. Tighten lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
14. 14

    Torque radius arm mounting bolts with vehicle at ride height
    With the vehicle weight now on the suspension (either fully lowered or with suspension loaded to simulate ride height using the floor jack), torque both the front and rear radius arm mounting bolts/nuts to specification. This ensures the bushings are torqued in their normal operating position, preventing premature bushing failure.
    ⚠Failure to torque radius arm bolts at ride height will cause premature bushing failure due to internal bushing wind-up.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat all steps for the opposite side radius arm
2. After both sides are complete, lower vehicle fully to the ground
3. Perform final torque verification of all fasteners
4. Re-torque wheel lug nuts after 50-100 miles of driving

Verification

• Test drive vehicle and verify elimination of clunking or wandering symptoms
• Verify steering returns to center properly after turns
• Inspect all fasteners for proper torque and cotter pin installation
• Schedule a professional wheel alignment within 100 miles, as radius arm bushing replacement will affect caster and camber settings

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