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

Warnings

Tools required

Parts

• Lower control arm assembly × 1 — Use OEM specification or quality aftermarket equivalent
• Cotter pin × 1 — Use OEM specification
• Control arm mounting bolts (if corroded or damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level, solid surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is still on ground (do not remove)
4. Raise front of vehicle with floor jack at approved jacking point
5. Support vehicle securely on jack stands placed at frame-approved lift points
6. Remove wheel completely
7. Spray penetrating lubricant on ball joint nut, cotter pin, and control arm bolts; allow to soak 10-15 minutes

Procedure

1. 1

   Remove ball joint cotter pin
   Locate the castle nut securing the lower ball joint to the steering knuckle. Straighten and remove the cotter pin using a punch and hammer. Discard the old cotter pin as a new one must be installed.
2. 2

   Remove ball joint castle nut
   Using a socket and breaker bar, remove the castle nut from the ball joint stud. Do not fully remove the nut initially - back it off until it is flush with the end of the stud to protect threads during separation.
3. 3

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the ball joint taper from the steering knuckle. Insert the tool between the control arm and knuckle, and strike firmly or apply pressure per tool design. Once taper breaks free, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠Control arm may drop suddenly when ball joint separates. Keep hands clear of pinch points.
4. 4

   Support lower control arm
   Place a floor jack under the outer end of the lower control arm to support its weight and control its descent during removal. This prevents damage to brake lines, ABS wiring, or CV axle components.
5. 5

   Remove front control arm bolt
   Locate the front control arm mounting bolt that secures the control arm to the front crossmember. Using a socket and breaker bar, remove this bolt completely. Note the orientation of any washers or spacers for reinstallation.
6. 6

   Remove rear control arm bolt
   Locate the rear control arm mounting bolt that secures the control arm to the rear mounting point on the crossmember. Remove this bolt completely. The control arm is now free and can be removed from the vehicle.
7. 7

   Remove lower control arm
   Carefully lower the jack supporting the control arm and maneuver the control arm out of the mounting position. Watch for any interference with brake lines, ABS sensors, or the CV axle. Remove the control arm from under the vehicle.
8. 8

   Clean mounting surfaces
   Use a wire brush to clean the control arm mounting points on the crossmember, removing any rust, debris, or old thread locker. Inspect the mounting bolt holes for thread damage or elongation. Clean the ball joint taper seat in the steering knuckle.
9. 9

   Install new lower control arm
   Position the new control arm into place, aligning the mounting points with the crossmember. Use the floor jack to support the outer end of the control arm and raise it to approximately the correct height for ball joint and bolt installation.
10. 10

    Install control arm mounting bolts
    Insert the front and rear control arm mounting bolts through the crossmember and control arm bushings. Thread the bolts in by hand to ensure proper alignment. Do NOT torque these bolts yet - they must be torqued with the vehicle weight on the suspension.
11. 11

    Connect ball joint to knuckle
    Raise the outer end of the control arm using the floor jack until the ball joint stud aligns with the hole in the steering knuckle. Insert the ball joint stud through the knuckle and thread on the castle nut. Tighten the nut to specification.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
12. 12

    Install new cotter pin
    Align the castle nut slots with the hole in the ball joint stud. If necessary, tighten the nut slightly (never loosen) to align the slots. Insert a new cotter pin through the stud hole and bend the ends to secure it properly.
    ℹ️Castle nut may be tightened beyond torque spec to align cotter pin hole, but never loosened below specification.
13. 13

    Reinstall wheel
    Place the wheel back onto the hub and thread on all lug nuts by hand. Tighten lug nuts in a star pattern with a socket, but do not torque to final specification yet.
14. 14

    Lower vehicle to load suspension
    Remove the jack stands and carefully lower the vehicle so the suspension is loaded with the vehicle weight on the wheels, but the vehicle is still slightly supported by the floor jack (wheels just touching the ground with partial weight). This loads the suspension bushings into their normal operating position.
15. 15

    Torque control arm bolts
    With the suspension loaded, torque the front and rear control arm mounting bolts to specification. This is critical - torquing these bolts with the suspension unloaded will cause premature bushing failure.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension. Failure to do so will cause bushing bind and premature wear.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
16. 16

    Final wheel installation
    Raise the vehicle completely off the ground and remove the floor jack. Lower the vehicle fully to the ground. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Ensure all fasteners are tightened to proper torque specifications
2. Verify cotter pin is properly installed and secured in ball joint castle nut
3. Confirm no brake lines, ABS wiring, or CV axle components are pinched or damaged

Verification

• Test drive vehicle at low speed and verify no unusual noises, clunks, or handling issues
• Perform visual inspection underneath to confirm all bolts are tight and cotter pin is secure
• Schedule a professional alignment as suspension geometry has been altered - alignment is required after lower control arm replacement

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