This procedure covers the replacement of the front upper control arm bushings on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including removal of the upper control arm and installation of new bushings.

Warnings

Tools required

Parts

• Front upper control arm bushing kit (left or right side) × 1 — Use OEM specification or equivalent
• Cotter pin (if equipped) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and support securely on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Apply penetrating oil to all control arm fasteners and ball joint nut, allow to soak

Procedure

1. 1

   Support lower control arm
   Position floor jack under the lower control arm near the ball joint to support the suspension weight and relieve tension on the upper components. Raise jack just enough to slightly compress the suspension.
2. 2

   Disconnect sway bar link if necessary
   If the sway bar link interferes with upper control arm removal, hold the shaft with an Allen key and remove the upper sway bar link nut. Disconnect the link from the upper control arm or strut.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove upper ball joint cotter pin and nut
   If equipped with a cotter pin, straighten the ends and pull the cotter pin from the ball joint stud. Using a socket and breaker bar, remove the upper ball joint nut completely. Keep the nut for reference during reassembly.
   ⚠Ball joint taper may release suddenly. Keep hands clear of pinch points.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper ball joint stud from the steering knuckle. Position the separator between the knuckle and control arm, then strike or compress until the taper releases. Avoid damaging the ball joint boot if reusing the control arm.
5. 5

   Remove upper control arm mounting bolts
   Locate the two bolts securing the upper control arm to the frame rail. These are typically accessed from underneath the vehicle. Using a socket, breaker bar, and torque wrench, remove both control arm mounting bolts completely. Note the orientation of any washers or sleeves.
   Torque spec

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

   Remove upper control arm
   Carefully maneuver the upper control arm out of the mounting location. You may need to lower or raise the floor jack slightly to create clearance. Inspect the ball joint and mounting points for wear or damage.
7. 7

   Press out old bushings
   Using a hydraulic press or control arm bushing press kit, press the old bushings out of the control arm. Position the control arm securely in the press with appropriate receiving cups to catch the bushing. Apply steady pressure until the bushing is completely removed. Repeat for the second bushing if applicable.
   ⚠Ensure press tooling is properly aligned before applying pressure. Misalignment can damage the control arm or cause tooling to slip.
8. 8

   Clean control arm bushing bores
   Use a wire brush to clean the bushing bores in the control arm, removing any rust, debris, or old bushing material. Inspect the bores for cracks or deformation. Wipe clean with a rag.
9. 9

   Press in new bushings
   Position the new bushing in the control arm bore, ensuring correct orientation per manufacturer instructions. Using the press and appropriate installation cups, apply steady pressure to press the new bushing into place until fully seated. The bushing should be flush or at the specified depth. Repeat for the second bushing if applicable.
   ℹ️Some bushings have orientation marks or voids that must align with control arm movement. Verify correct orientation before pressing.
10. 10

    Install control arm to frame
    Position the control arm with new bushings into the frame mounting location. Insert both control arm mounting bolts through the bushings and into the frame. Thread the bolts by hand initially. Do NOT torque at this time - bolts must be torqued with vehicle weight on suspension.
11. 11

    Connect ball joint to knuckle
    Raise or lower the floor jack supporting the lower control arm to align the upper ball joint stud with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and thread the ball joint nut onto the stud. Tighten the nut to specification.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
12. 12

    Install new cotter pin if equipped
    If the ball joint uses a cotter pin, align the castellations on the nut with the hole in the ball joint stud. Insert a new cotter pin through the stud and bend the ends to secure. If the hole does not align, tighten the nut slightly (no more than 1/6 turn) until alignment is achieved. Never loosen the nut to align.
13. 13

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the upper control arm or strut. Hold the shaft with an Allen key and tighten the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
14. 14

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and hand-tighten the lug nuts in a star pattern. Remove the floor jack from under the lower control arm. Lower the vehicle until the suspension is at normal ride height but the wheel is not yet bearing full weight. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
15. 15

    Torque control arm bolts with vehicle weight on suspension
    With the vehicle at normal ride height and suspension loaded, torque both upper control arm mounting bolts to specification. This critical step ensures the bushings are not pre-twisted, which would cause premature failure. After torquing, lower the vehicle completely to the ground.
    ⚠Failure to torque control arm bolts with suspension loaded will result in premature bushing failure and require repeat repairs.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are tightened to proper specifications
2. Verify cotter pin is properly installed and secured if applicable
3. Double-check that control arm bolts were torqued with vehicle weight on suspension

Verification

• Test drive the vehicle at low speed and verify no unusual noises from the front suspension
• Check for proper steering response and wheel alignment
• Inspect all connections for tightness after initial test drive
• Schedule a professional wheel alignment as bushing replacement affects suspension geometry

More procedures for this vehicle