This procedure replaces the front upper control arm bushings on a 2015-2020 Ford F-150 with 5.0L V8 engine, requiring removal of the control arm assembly and pressing in new bushings.

Warnings

Tools required

Parts

• Front upper control arm bushing set × 2 — Use OEM specification or Moog K201596
• Cotter pin for ball joint × 1 — Use OEM specification
• Anti-seize compound × 1 — Use high-temperature variety

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Spray all upper control arm mounting bolts and ball joint nut with penetrating oil and allow to soak for 15-20 minutes
4. Mark the orientation of the old bushings before removal for proper installation reference

Procedure

1. 1

   Remove wheel
   Loosen wheel lug nuts while vehicle is on ground. Raise front of vehicle with floor jack at designated front jacking point. Support vehicle securely on jack stands placed under frame rails. Remove wheel completely.
2. 2

   Access upper control arm
   Locate the upper control arm at the top of the steering knuckle. The upper ball joint connects the control arm to the knuckle, and the control arm mounts to the frame with two bolts at the rear.
3. 3

   Remove upper ball joint cotter pin and nut
   Remove and discard the cotter pin from the upper ball joint stud. Using a 21mm socket, remove the ball joint castle nut. Do not reuse the old cotter pin.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint from the steering knuckle. Position the separator between the knuckle and control arm, and apply force to break the taper fit. Avoid damaging the ball joint boot if reusing the control arm.
   ⚠Ball joint separator tools can slip under pressure. Keep hands clear of pinch points.
5. 5

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that secure the control arm to the frame bracket. Using an 18mm socket and breaker bar, remove both front and rear control arm mounting bolts. Support the control arm as you remove the second bolt to prevent it from falling.
6. 6

   Remove control arm assembly
   Remove the upper control arm assembly from the vehicle. Maneuver it out from between the frame and steering knuckle. Inspect the ball joint and control arm for any damage, cracks, or excessive wear.
7. 7

   Press out old bushings
   Secure the control arm in a hydraulic press or use a specialized control arm bushing removal tool. Note the orientation and depth of the existing bushings. Using the appropriate size press adapters, carefully press out both control arm bushings. The bushings are interference fit and will require significant force. Ensure the control arm is properly supported to prevent distortion.
   ⚠️Hydraulic presses generate extreme force. Ensure control arm and adapters are properly aligned before applying pressure to prevent part ejection.
8. 8

   Clean bushing bores
   Use a wire brush to thoroughly clean the bushing bores in the control arm. Remove all rust, debris, and old bushing material. Inspect the bores for any damage or deformation. Apply a thin coat of anti-seize compound to the bushing bores.
9. 9

   Install new bushings
   Position the new bushings at the control arm mounting points, ensuring correct orientation matching your reference marks. The voids in the bushings should align with the control arm mounting bolt angle. Using the hydraulic press and appropriate adapters, press the new bushings into the control arm bores until fully seated and flush. Press evenly to avoid cocking the bushing in the bore.
   ⚠Bushing orientation is critical for proper suspension geometry. Incorrect installation will cause premature bushing failure.
10. 10

    Install control arm to frame
    Position the control arm assembly back into the frame bracket. Insert both front and rear control arm mounting bolts through the frame bracket and new bushings. Thread the bolts by hand but do NOT torque at this time. Bolts must be torqued with vehicle weight on suspension.
11. 11

    Connect ball joint to knuckle
    Align the upper ball joint stud with the hole in the steering knuckle. You may need to use a pry bar to position the knuckle. Insert the ball joint stud through the knuckle and install the castle nut hand-tight.
12. 12

    Torque ball joint nut and install cotter pin
    Using a torque wrench and 21mm socket, torque the upper ball joint castle nut to specification. The castellations must align with the cotter pin hole. If needed, tighten slightly more (never loosen) to align the nearest castellation. Install a new cotter pin through the castle nut and ball joint stud, then bend the ends to secure.
    Torque spec

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

    Reinstall wheel
    Mount the wheel back onto the hub. Install lug nuts hand-tight. Lower the vehicle until the tire just contacts the ground but the suspension is not yet fully loaded.
14. 14

    Torque control arm bolts with vehicle weight on suspension
    With the vehicle lowered and weight on the suspension (tire on ground), torque both control arm mounting bolts to specification using an 18mm socket and torque wrench. This is critical - torquing with suspension unloaded will preload the bushings incorrectly and cause premature failure.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension. Failure to do so will cause bushing binding and premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
15. 15

    Final wheel installation
    Fully lower the vehicle to the ground. Using a torque wrench, torque the wheel lug nuts to specification in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Repeat procedure for opposite side if replacing both upper control arm bushings
2. Verify all fasteners are torqued to specification
3. Ensure new cotter pin is properly installed and secured on ball joint

Verification

• Test drive vehicle at low speed and verify no abnormal noises from front suspension
• Check for proper steering response and no pulling to either side
• After 50-100 miles of driving, re-torque control arm mounting bolts with vehicle weight on suspension
• Schedule front end alignment as suspension geometry may have changed during repair

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