This procedure covers the removal and replacement of worn leaf spring bushings on the rear suspension of a 2015-2020 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Leaf spring front bushing (per side) × 2 — Use OEM specification
• Leaf spring rear bushing (per side) × 2 — Use OEM specification
• Leaf spring pivot bolts (if corroded) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Place wheel chocks in front of both front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support securely on jack stands at frame rails
5. Remove rear wheels completely
6. Spray all leaf spring pivot bolts and shackle bolts with penetrating oil

Procedure

1. 1

   Support rear axle
   Position a floor jack under the rear axle housing near the side being serviced. Raise jack just enough to make contact and slightly compress the leaf spring. This relieves tension on the bushings and mounting hardware.
2. 2

   Remove U-bolts
   Remove the nuts from the U-bolts that secure the leaf spring to the axle housing. Remove the U-bolts and the bottom plate. Lower the jack slightly to separate the axle from the leaf spring, but maintain support under the axle.
3. 3

   Remove rear shackle assembly
   Locate the rear shackle at the back of the leaf spring. Remove the bolt securing the shackle to the frame bracket and the bolt securing the shackle to the rear of the leaf spring. Remove the shackle assembly and note the orientation of any washers or spacers.
4. 4

   Remove front pivot bolt
   Remove the large pivot bolt and nut that secures the front eye of the leaf spring to the front hanger bracket on the frame. Use a breaker bar if necessary. Support the leaf spring to prevent it from dropping when the bolt is removed.
5. 5

   Remove leaf spring assembly
   Carefully lower and remove the leaf spring assembly from the vehicle. Place it on a stable work surface for bushing replacement. Inspect the spring for cracks or damage while removed.
6. 6

   Press out front bushing
   Using a leaf spring bushing press kit or hydraulic press, press the old front bushing out of the spring eye. Apply pressure evenly and ensure the spring eye is properly supported to prevent distortion. Clean the inside of the spring eye with a wire brush and inspect for damage or elongation.
7. 7

   Install new front bushing
   Lubricate the new front bushing with soapy water or bushing installation lubricant. Position the bushing squarely in the spring eye and press it in using the bushing press. Ensure the bushing is fully seated and centered in the eye. The bushing should be flush or slightly recessed per manufacturer specifications.
8. 8

   Replace rear shackle bushings
   Press out the old bushing from the rear eye of the leaf spring using the same method as the front. If replacing shackle bushings in the shackle itself, press those out as well. Install new bushings ensuring proper orientation and full seating. Clean all surfaces before installation.
9. 9

   Reinstall leaf spring assembly
   Position the leaf spring back into the vehicle. Insert the front pivot bolt through the front hanger bracket and spring eye. Install the nut finger-tight only at this stage. Do not torque yet.
10. 10

    Attach rear shackle
    Install the rear shackle assembly connecting the rear of the leaf spring to the frame bracket. Insert both shackle bolts and install nuts finger-tight. Ensure all washers and spacers are in their original positions.
11. 11

    Reinstall U-bolts and axle
    Raise the floor jack to lift the axle housing back into contact with the leaf spring. Position the spring center pin in the axle housing locator hole. Install the bottom plate and U-bolts. Thread nuts onto U-bolts and tighten in a criss-cross pattern to manufacturer specification (typically 100-120 lb-ft, but verify in service manual as this torque is not provided in database).
12. 12

    Reinstall wheels
    Install the rear wheel and thread lug nuts by hand. Lower the vehicle until the tire just contacts the ground but the suspension is not fully loaded. Torque wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
13. 13

    Final torque under load
    Completely lower the vehicle so full weight is on the suspension. This loads the bushings in their normal operating position. Torque the front pivot bolt and rear shackle bolts to manufacturer specification (typically 150-200 lb-ft for leaf spring pivot hardware, but verify in service manual as these specific torques are not provided in database). Bushings must be torqued at ride height to prevent premature wear.

Reassembly

1. If replacing bushings on both sides, repeat entire procedure for opposite side
2. Verify all fasteners are properly torqued before test driving
3. All leaf spring pivot hardware must be torqued with vehicle at normal ride height to ensure bushing longevity

Verification

• Test drive vehicle and verify no abnormal noises from rear suspension
• Check for proper rear axle alignment and no pulling to one side
• Inspect all mounting hardware for proper tightness after 50-100 miles of driving
• Verify no binding or squeaking from new bushings during suspension articulation

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