This procedure covers removal and replacement of the front upper control arm on a 2011-2014 Ford F-150 with 5.0L V8 4WD, including ball joint separation and proper torque specifications.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM Ford or equivalent aftermarket
• Ball joint castellated nut (if not included with control arm) × 1 — Use OEM specification
• Cotter pin × 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 side being serviced
5. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes
6. Place floor jack under lower control arm to support suspension weight

Procedure

1. 1

   Remove ball joint cotter pin
   Locate the upper ball joint stud at the top of the steering knuckle. Straighten and remove the cotter pin from the ball joint castellated nut. Discard the old cotter pin.
2. 2

   Loosen ball joint nut
   Using a 21mm socket, loosen the ball joint nut but do not remove it completely. Leave the nut threaded on 3-4 turns to protect the threads and prevent the knuckle from dropping when the taper is separated.
   Torque spec

   Ball Joint Nut115 Nm (85 lb-ft)
3. 3

   Separate ball joint from knuckle
   Position the ball joint separator tool between the upper control arm and the steering knuckle. Apply force to break the tapered connection. If using a pickle fork, insert it between the ball joint boot and knuckle (this will damage the boot). Once the taper is broken, remove the ball joint nut completely and allow the knuckle to drop away from the upper control arm.
   ⚠Ensure floor jack is supporting the lower control arm before separating the ball joint to prevent sudden dropping of the suspension.
4. 4

   Remove front upper control arm mounting bolt
   Locate the forward mounting bolt that secures the upper control arm to the frame bracket. Using a 19mm socket and breaker bar, remove the bolt completely. The bolt passes through a bushing in the control arm.
   Torque spec

   Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
5. 5

   Remove rear upper control arm mounting bolt
   Locate the rear mounting bolt securing the upper control arm to the frame bracket. Using a 19mm socket and breaker bar, remove this bolt completely. Support the control arm as you remove the final bolt.
   Torque spec

   Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
6. 6

   Remove upper control arm
   With both mounting bolts removed, maneuver the upper control arm out of the mounting bracket and away from the vehicle. Inspect the mounting area on the frame for corrosion or damage.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting bracket surfaces and bolt holes. Remove any corrosion, dirt, or debris. Inspect the frame bracket for cracks or damage. Clean the threads of the mounting bolts with a wire brush if reusing.
8. 8

   Install new upper control arm
   Position the new upper control arm into the frame mounting bracket. Align the bushings with the mounting holes. Insert both front and rear mounting bolts finger-tight. Do not torque these bolts yet - they must be torqued at ride height.
   ℹ️Verify the control arm is oriented correctly with the ball joint pointing downward before installing mounting bolts.
9. 9

   Connect ball joint to knuckle
   Raise the steering knuckle using the floor jack under the lower control arm until the upper ball joint stud inserts into the knuckle hole. Install the new castellated nut onto the ball joint stud and tighten to specification using a 21mm socket and torque wrench.
   Torque spec

   Ball Joint Nut115 Nm (85 lb-ft)
10. 10

    Install cotter pin
    Align the castellations of the nut with the hole in the ball joint stud. If necessary, tighten the nut slightly (never loosen) to align the nearest castellation with the hole. Insert a new cotter pin through the hole and bend the ends to secure.
11. 11

    Reinstall wheel
    Place the wheel back onto the hub and thread all lug nuts by hand. Tighten the lug nuts in a star pattern to bring the wheel flush against the hub, but do not torque yet.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
12. 12

    Lower vehicle to ride height
    Carefully lower the vehicle from the jack stands until the suspension is at normal ride height with the tires supporting the vehicle weight. The vehicle can rest on the ground or be supported just enough to allow access to the control arm bolts while maintaining suspension load.
    ⚠Control arm mounting bolts must be torqued with the suspension at ride height to prevent premature bushing wear.
13. 13

    Torque control arm mounting bolts
    With the vehicle at ride height and suspension loaded, torque both the front and rear upper control arm-to-frame mounting bolts to specification using a 19mm socket and torque wrench.
    Torque spec

    Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
14. 14

    Torque wheel lug nuts
    With the vehicle on the ground, torque all wheel lug nuts to specification in a star pattern using the proper socket and torque wrench.
    Torque spec

    Wheel Lug Nuts169 Nm (125 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 at ride height

Verification

• Test drive the vehicle and verify no unusual noises from the front suspension
• Check for proper steering response and alignment feel
• Schedule a professional wheel alignment as camber and caster angles have been affected by control arm replacement
• After 50-100 miles, re-check all fastener torques to ensure nothing has loosened

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