This procedure covers removal and replacement of the upper control arm on the front suspension of a 2011-2014 Ford F-150 with 5.0L V8 4WD.

Warnings

Tools required

Parts

• Upper control arm × 1 — Use OEM specification or quality aftermarket equivalent
• Upper ball joint castle nut (if not reusable) × 1 — Use OEM specification
• Cotter pin × 1 — New cotter pin for ball joint

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle using floor jack at manufacturer-designated lift point
5. Support vehicle securely on jack stands placed under frame rails
6. Remove wheel and tire assembly completely
7. Spray penetrating oil on upper control arm bolts and ball joint nut, allow to soak

Procedure

1. 1

   Remove brake caliper brackets if needed for clearance
   On some F-150 configurations, the brake caliper assembly may interfere with control arm removal. If necessary, remove the caliper mounting bolts and secure the caliper assembly to the frame using mechanics wire. Do not allow caliper to hang by the brake hose.
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint at the steering knuckle. Remove and discard the cotter pin. Using a socket and breaker bar, remove the castle nut from the upper ball joint stud. Do not reuse the castle nut if threads are damaged.
   Torque spec

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

   Separate ball joint from steering knuckle
   Position ball joint separator tool between the upper control arm and steering knuckle. Apply force to separate the ball joint taper from the knuckle. Once the taper breaks free, the knuckle will drop down. Support the knuckle assembly to prevent damage to brake hoses or ABS wiring.
   ⚠The knuckle will drop suddenly when the ball joint releases. Be prepared to support its weight.
4. 4

   Support the lower control arm
   Place a floor jack or jack stand under the lower control arm to support the coil spring tension. This prevents the suspension from dropping excessively and provides stability during upper control arm removal.
5. 5

   Remove upper control arm mounting bolts
   Locate the two control arm mounting bolts connecting the upper control arm to the frame bracket. These bolts pass through rubber bushings in the control arm. Use a socket and breaker bar to remove both bolts completely. Note the orientation of any washers or spacers for reinstallation.
   Torque spec

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

   Remove upper control arm from vehicle
   Carefully maneuver the upper control arm out of the wheel well area. It may be necessary to angle the arm or rotate it to clear the coil spring and frame components. Inspect the ball joint boot and bushings on the removed arm.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the control arm mounting bracket on the frame. Remove any rust, dirt, or debris from the bolt holes and mounting surfaces. Inspect the frame bracket for cracks or damage.
8. 8

   Install new upper control arm
   Position the new upper control arm into the frame mounting bracket. Align the bolt holes in the control arm bushings with the frame bracket holes. Insert both control arm mounting bolts from the same direction as original installation. Thread bolts by hand to ensure proper alignment.
   ⚠Do not fully torque control arm bolts at this time. Bolts must be torqued with vehicle weight on wheels.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
9. 9

   Tighten control arm bolts to initial snug position
   With the vehicle still raised on jack stands, tighten the control arm mounting bolts until snug but not to final torque specification. The bolts should be tight enough to hold the arm in place but still allow bushing movement.
10. 10

    Connect ball joint to steering knuckle
    Raise the steering knuckle assembly into position and align the upper ball joint stud with the hole in the knuckle. Install the new castle nut onto the ball joint stud. Tighten the nut to the specified torque of 110 Nm (81 lb-ft). Continue tightening if necessary to align the castle nut slots with the cotter pin hole in the stud. Install a new cotter pin and bend the ends to secure.
    Torque spec

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

    Reinstall brake caliper if removed
    If the brake caliper assembly was removed for clearance, reinstall it to the mounting bracket and torque the mounting bolts to specification. Remove any mechanics wire used to support the caliper.
12. 12

    Reinstall wheel and lower vehicle
    Install the wheel and tire assembly. Thread all lug nuts by hand, then tighten in a star pattern while vehicle is still on jack stands. Carefully lower the vehicle until the tire contacts the ground but full weight is not yet on the suspension. Remove jack stands and lower vehicle completely to the ground.
    Torque spec

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

    Torque control arm bolts with vehicle at ride height
    With the vehicle on the ground at normal ride height, rock the vehicle side-to-side several times to settle the suspension. Crawl under the vehicle and torque both upper control arm mounting bolts to the final specification of 165 Nm (122 lb-ft). This ensures the control arm bushings are torqued in their normal operating position.
    ⚠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)
14. 14

    Final torque wheel lug nuts
    With the vehicle on the ground, perform final torque on all wheel lug nuts to 169 Nm (125 lb-ft) in a star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Repeat procedure for opposite side if replacing both upper control arms
2. Ensure all fasteners are torqued to specification
3. Verify brake caliper is properly secured and brake hose is not kinked or stretched

Verification

• Start vehicle and turn steering wheel lock-to-lock while stationary to verify no binding or interference
• Perform a test drive at low speed and verify normal steering feel and no unusual noises
• Check for any fluid leaks around brake components
• Schedule professional wheel alignment immediately - camber and caster will be out of specification after control arm replacement
• After 50-100 miles, re-verify torque on control arm bolts and wheel lug nuts

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