This procedure covers the replacement of the air suspension height sensor on a 2015-2020 Ford F-150 with air suspension, typically located at the rear suspension control arm or axle.

Warnings

Tools required

Parts

• Air suspension height sensor × 1 — Use OEM Ford specification for air suspension system
• Height sensor mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition to ON position (engine off) and access air suspension controls in vehicle settings
3. Deactivate air suspension system using the dashboard switch or infotainment system (suspension will lower to preset height)
4. Turn ignition OFF and wait 2 minutes for system to fully depressurize
5. Chock front wheels securely

Procedure

1. 1

   Access the rear suspension area
   Loosen rear wheel lug nuts one full turn while vehicle is on ground. Raise rear of vehicle using jack at manufacturer-specified jacking point on frame rail. Support vehicle on jack stands positioned at frame rails behind rear axle. Remove rear wheel on side requiring sensor replacement.
   Torque spec

   Wheel Lug Nuts156 Nm (115 lb-ft)
2. 2

   Locate the height sensor
   Identify the height sensor mounted to the rear axle housing or control arm. The sensor consists of a body mounted to the axle/arm with a connecting link rod attached to the frame or opposite suspension component. Note the sensor orientation and link rod position for proper reassembly.
   ℹ️Take a photo of sensor orientation and link rod angle before removal to ensure correct reinstallation position
3. 3

   Disconnect the electrical connector
   Locate the electrical connector on the height sensor body. Press the connector release tab and carefully pull connector straight away from sensor. Inspect connector pins for corrosion or damage. If connector is corroded, clean with electrical contact cleaner.
   ⚠Do not pull on wires - only pull on connector body to avoid damaging wiring harness
4. 4

   Remove the sensor link rod
   Locate the plastic ball socket connector at the end of the sensor link rod where it attaches to the frame bracket or suspension component. Pry the ball socket retaining clip off using a small flathead screwdriver or trim tool. Pull link rod ball stud from socket. If link rod is attached to sensor with a clip, remove clip and separate link from sensor body.
   ℹ️Link rod ball socket clips are often single-use - inspect for damage and replace if necessary
5. 5

   Remove sensor mounting fasteners
   Remove the mounting bolts securing the height sensor body to the axle housing or control arm bracket. There are typically two bolts. If fasteners are corroded, apply penetrating oil and allow to soak for 5-10 minutes before removal. Keep fasteners if in good condition for reuse.
   ⚠Support sensor body while removing final fastener to prevent dropping and damaging sensor or surrounding components
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove the old height sensor
   Carefully remove the height sensor assembly from the mounting bracket. Inspect the mounting bracket on axle or control arm for damage, cracks, or excessive corrosion. If bracket is damaged, it must be replaced before installing new sensor. Clean mounting surface with wire brush to remove rust and debris.
   ℹ️Verify replacement sensor part number matches original sensor - different trim levels may use different sensor ranges
7. 7

   Install new height sensor
   Position new height sensor on mounting bracket in same orientation as original sensor. Install mounting bolts hand-tight initially. Ensure sensor body is properly seated against mounting bracket before tightening. Torque mounting bolts to specification in a cross pattern if multiple bolts are present.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Reconnect sensor link rod
   Align sensor link rod ball stud with socket on frame bracket or opposite suspension component. Press ball stud firmly into socket until it seats completely. Install new retaining clip to secure ball socket connection. Verify link rod has appropriate free play and is not binding or over-extended.
   ⚠Ensure link rod is at approximately mid-range position - if over-extended or compressed, sensor may be installed incorrectly
9. 9

   Reconnect electrical connector
   Align electrical connector with sensor terminal and push firmly until connector clicks into locked position. Gently pull on connector to verify it is fully seated and locked. Route wiring harness to match original path and secure any clips or ties that were removed.
10. 10

    Reinstall wheel and lower vehicle
    Reinstall rear wheel and hand-tighten lug nuts in star pattern. Lower vehicle until tire just contacts ground but weight is still on jack stands. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands. Perform final lug nut torque check with full vehicle weight on ground.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
11. 11

    Reactivate air suspension and calibrate sensor
    Turn ignition to ON position. Reactivate air suspension system using dashboard switch or infotainment controls. Connect scan tool and clear any stored suspension fault codes. Follow scan tool manufacturer procedure to calibrate new height sensor if required. Cycle suspension through all height positions (entry, normal, off-road) to verify proper operation.
    ℹ️Some Ford models perform automatic sensor calibration during first drive cycle, while others require manual calibration with scan tool

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Confirm sensor link rod is properly secured with new retaining clip
3. Check that sensor mounting bolts are torqued to specification
4. Ensure no tools or parts were left in wheel well area

Verification

• With scan tool connected, verify no active suspension fault codes are present
• Test air suspension operation through all height settings - suspension should raise and lower smoothly
• Drive vehicle and verify suspension adjusts properly based on speed and load conditions
• Recheck suspension system with scan tool after 5-10 mile test drive to confirm no new fault codes
• Verify height sensor reading on scan tool changes appropriately when manually moving suspension up and down (with suspension deactivated)

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