This procedure covers removal and replacement of the rear upper control arm on a 2011-2014 Ford F-150 4WD with 5.0L V8, including disconnection of the ball joint and control arm mounting bolts.

Warnings

Tools required

Parts

• Rear upper control arm assembly × 1 — Use OEM specification or quality aftermarket equivalent
• Ball joint castle nut (if not included with control arm) × 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. Place wheel chocks in front of and behind front wheels
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise rear of vehicle with floor jack at rear axle or frame lifting point
5. Support vehicle on jack stands placed at manufacturer-specified frame jacking points
6. Remove rear wheel completely
7. Spray penetrating oil on ball joint nut, control arm bolts, and mounting hardware; allow to soak 10-15 minutes

Procedure

1. 1

   Support the rear knuckle assembly
   Position a floor jack under the rear knuckle/axle assembly near the control arm mounting point. Raise jack slightly to take load off the upper control arm and prevent the suspension from dropping when the ball joint is disconnected. The jack should support the weight but not lift the vehicle.
2. 2

   Remove ball joint cotter pin and castle nut
   Locate the upper control arm ball joint where it connects to the rear knuckle. Remove and discard the cotter pin from the castle nut. Using a socket and breaker bar, remove the ball joint castle nut completely. Note the orientation of the ball joint stud for reassembly.
   Torque spec

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

   Separate the ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper control arm ball joint from the knuckle. Insert the tool between the knuckle and control arm, then strike with hammer or use mechanical separator to break the taper. Avoid damaging the knuckle surface. If reusing the ball joint boot, use a puller-type separator rather than a pickle fork.
   ⚠The knuckle assembly may shift suddenly when the ball joint separates. Ensure floor jack is properly positioned to support the assembly.
4. 4

   Mark control arm position
   Before removing the control arm mounting bolts, use a paint pen or marker to mark the position of the control arm relative to the frame mounting brackets. This will help with initial alignment during installation and reduce the magnitude of alignment correction needed afterward.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame bracket. Using a socket and breaker bar, remove the bolt and nut completely. The bolt may be tight due to the weight on the bushing. If the bushing rotates instead of the bolt, hold the bolt head while turning the nut.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the frame bracket. Using a socket and breaker bar, remove the bolt and nut completely. Support the control arm by hand as you remove the final fastener to prevent it from falling.
   Torque spec

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

   Remove upper control arm from vehicle
   With both mounting bolts removed and ball joint disconnected, remove the upper control arm from the vehicle. Inspect the frame mounting brackets for damage, corrosion, or deformation. Clean the mounting surfaces with a wire brush if needed.
8. 8

   Prepare new control arm for installation
   Compare the new control arm to the old arm to verify correct part. Inspect the ball joint boot for damage and ensure it moves freely through its range of motion. If the new arm includes new hardware, verify you have all necessary bolts, nuts, and cotter pins.
9. 9

   Install new control arm to frame brackets
   Position the new upper control arm into the frame mounting brackets, aligning with the reference marks made during disassembly. Insert both front and rear mounting bolts through the control arm bushings and frame brackets. Thread nuts onto bolts finger-tight only. Do not torque at this time as bolts must be torqued with vehicle weight on wheels.
   ℹ️Control arm mounting bolts must remain loose until vehicle is lowered to the ground with full weight on suspension.
10. 10

    Connect ball joint to knuckle
    Align the control arm ball joint stud with the hole in the rear knuckle. You may need to adjust the floor jack height slightly to align the components. Insert the ball joint stud through the knuckle and thread on the new castle nut. Tighten the castle nut to specification.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
11. 11

    Install new cotter pin
    Install a new cotter pin through the castle nut and ball joint stud. If the castle nut slots do not align with the stud hole, tighten the nut slightly (do not loosen) until alignment is achieved. Bend the cotter pin ends to secure properly.
    ⚠Never loosen the castle nut to align cotter pin holes. Only tighten further if needed for alignment.
12. 12

    Reinstall wheel and lower vehicle
    Remove the floor jack from under the knuckle assembly. Reinstall the rear wheel and thread lug nuts on by hand. Lower the vehicle until the tire just makes contact with the ground but the full weight is still on jack stands. Tighten lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
13. 13

    Torque control arm bolts with vehicle at ride height
    With the vehicle still supported by jack stands but with tire touching ground, have an assistant sit in the driver's seat or place equivalent weight (approximately 150-175 lbs) in the vehicle to simulate ride height. Alternatively, lower vehicle completely to ground. Torque both front and rear control arm mounting bolts to specification. This critical step ensures bushings are torqued at the correct position to prevent premature wear.
    ⚠Failure to torque control arm bolts at ride height will cause premature bushing failure and abnormal handling.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final lowering and torque verification
    Fully lower the vehicle to the ground and remove jack stands. Bounce the rear suspension several times to settle components. Verify all fasteners are tight and double-check the ball joint cotter pin is properly installed and secured.

Reassembly

1. Ensure the cotter pin is properly bent and secured on the ball joint castle nut
2. Verify all torque specifications were met, particularly the control arm bolts which must be torqued at ride height
3. Confirm no tools or parts were left in the suspension area

Verification

• Test drive vehicle at low speed and verify no unusual noises from rear suspension
• Check for any clunking or loose feeling when going over bumps
• Verify steering tracks straight (though alignment will be needed)
• Schedule a four-wheel alignment as soon as possible, as camber and toe settings have been affected
• After 50-100 miles, re-check torque on control arm mounting bolts and ball joint castle nut

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