This procedure covers the removal and replacement of the upper control arm on a 2015-2020 Ford F-150 with 5.0L V8 engine, including disconnection of the ball joint and control arm mounting points.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or equivalent
• Cotter pin for ball joint × 1 — Standard size for F-150

Preparation

1. Park vehicle on level, solid surface 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 with floor jack at manufacturer-recommended lift point
5. Support vehicle securely on jack stands placed under frame rails
6. Remove wheel completely and set aside

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack slightly to compress the suspension and relieve tension on the upper control arm. This prevents the knuckle from dropping when the upper ball joint is disconnected.
2. 2

   Remove the upper ball joint cotter pin
   Locate the upper ball joint castle nut at the top of the steering knuckle. Use a punch and hammer to straighten and drive out the cotter pin. Discard the old cotter pin as it cannot be reused.
3. 3

   Loosen the upper ball joint nut
   Using a socket and breaker bar, loosen the upper ball joint castle nut but do not remove it completely. Leave it threaded on a few turns to prevent the knuckle from separating violently when the taper is broken.
4. 4

   Separate the ball joint taper
   Position a ball joint separator or pickle fork between the upper control arm and the steering knuckle. Strike the tool firmly with a hammer to break the ball joint taper free. Once separated, remove the castle nut completely and lower the knuckle away from the control arm using the floor jack under the lower control arm.
   ⚠A pickle fork will damage the ball joint boot. Only use if replacing the control arm or ball joint.
5. 5

   Remove the front control arm mounting bolt
   Locate the front control arm mounting bolt that secures the control arm to the frame. This is typically a cam bolt for alignment adjustment. Using a socket and breaker bar, remove the bolt and any alignment cam washers. Note the orientation and position of cam washers for reassembly to maintain approximate alignment.
6. 6

   Remove the rear control arm mounting bolt
   Locate the rear control arm mounting bolt at the frame bracket. Remove this bolt using a socket and breaker bar. Support the control arm by hand as you remove the final bolt to prevent it from falling.
7. 7

   Remove the upper control arm
   Carefully maneuver the upper control arm out of the mounting position. It may be necessary to angle or rotate the arm to clear surrounding components. Inspect the mounting points on the frame for damage or excessive corrosion.
8. 8

   Prepare the new control arm and mounting points
   Clean the frame mounting surfaces with a wire brush to remove rust and debris. Apply a thin coat of anti-seize to bolt threads if desired. If the new control arm has a serviceable ball joint, verify the ball joint stud is clean and free of debris. Compare the new control arm to the old one to ensure correct fitment.
9. 9

   Install the new upper control arm
   Position the new upper control arm into the frame mounting brackets. Thread the front mounting bolt (with cam washers in their original orientation) and rear mounting bolt by hand. Do not tighten at this time. The bolts should be snug enough to hold the arm in place but still allow movement.
10. 10

    Connect the ball joint to the knuckle
    Use the floor jack to raise the steering knuckle up to the ball joint stud. Clean the ball joint taper and knuckle bore if necessary. Insert the ball joint stud through the knuckle and thread on the new castle nut. Tighten the nut to the specified torque, then continue tightening if necessary until the cotter pin hole aligns with a castle slot.
    ⚠Never loosen the castle nut to align the cotter pin hole. Only tighten further to achieve alignment.
    Torque spec

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

    Install new cotter pin
    Insert a new cotter pin through the castle nut and ball joint stud. Bend the ends of the cotter pin in opposite directions to secure it in place and prevent the castle nut from loosening.
12. 12

    Reinstall the wheel
    Mount the wheel back onto the hub and thread all lug nuts by hand. Tighten the lug nuts in a star pattern until the wheel is snug against the hub, but do not torque yet.
13. 13

    Lower vehicle to load suspension
    Carefully lower the vehicle from the jack stands until the full weight is on the wheels but the jack stands are still in contact for safety. The suspension must be at normal ride height with vehicle weight on the wheels before torquing control arm bolts.
    ℹ️This step is critical. Torquing control arm bolts with suspension hanging will cause bushing bind and premature failure.
14. 14

    Torque control arm mounting bolts
    With the vehicle weight on the wheels at normal ride height, torque the front and rear control arm mounting bolts to specification. Ensure the vehicle remains stable on the jack stands during this process.
    Torque spec

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

    Final lowering and wheel torque
    Remove the jack stands and lower the vehicle completely to the ground. 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. Verify all fasteners are properly torqued and the new cotter pin is secure
2. Remove wheel chocks and test drive vehicle at low speed to verify proper installation
3. A professional wheel alignment is strongly recommended after control arm replacement to ensure proper tire wear and handling characteristics

Verification

• Verify the ball joint castle nut is torqued correctly and secured with a new cotter pin
• Confirm control arm mounting bolts were torqued with vehicle weight on wheels
• Check that there is no excessive play or noise from the upper ball joint
• Test drive at low speed and verify steering feels normal with no pulling or unusual noises
• Schedule a professional wheel alignment to set camber, caster, and toe to factory specifications

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