This procedure covers the removal and replacement of the upper control arm on the front suspension of a 2015-2020 Ford F-150 with 5.0L V8 engine.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or equivalent
• Upper ball joint nut × 1 — Replace if damaged

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support on jack stands at frame rails
5. Remove front wheel on side being serviced
6. Spray all fasteners with penetrating oil if corrosion is present

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. Raise the jack just enough to take the load off the upper control arm but not to lift the vehicle. This prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Remove upper ball joint castle nut
   Remove the cotter pin from the upper ball joint stud. Using a 21mm socket, remove the castle nut from the upper ball joint. Do not reuse the castle nut if threads are damaged.
3. 3

   Separate the ball joint from knuckle
   Using a ball joint separator or pickle fork, separate the upper ball joint stud from the steering knuckle. Insert the tool between the knuckle and control arm, and drive or pry the joint apart. Avoid damaging the ball joint boot if reusing the control arm. Once separated, support the knuckle to prevent strain on brake hose.
   ⚠Do not strike the ball joint stud directly with a hammer as this can damage the threads and stud taper.
4. 4

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the upper control arm to the frame bracket. Using an 18mm wrench to hold the nut and a 21mm socket on the bolt head, remove the front control arm-to-frame bolt. Note the orientation of the bolt for reinstallation.
5. 5

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the upper control arm to the frame bracket. Using an 18mm wrench to hold the nut and a 21mm socket on the bolt head, remove the rear control arm-to-frame bolt. Support the control arm as you remove the final fastener.
6. 6

   Remove upper control arm
   Once both mounting bolts are removed, carefully maneuver the upper control arm out of the frame bracket and away from the vehicle. Inspect the frame mounting brackets for damage, cracks, or excessive wear.
7. 7

   Prepare new upper control arm
   Compare the new upper control arm to the old unit to verify correct part. Inspect the ball joint boot for damage and ensure all grease fittings are present if equipped. Clean the frame mounting areas with a wire brush to remove rust and debris.
8. 8

   Install new upper control arm to frame
   Position the new upper control arm into the frame brackets. Insert the front and rear mounting bolts through the frame brackets and control arm bushings. Start the nuts on the bolts but do not tighten at this time. The bushings must be torqued at ride height.
   ⚠Do not fully torque the control arm mounting bolts until the vehicle is at ride height to prevent bushing bind and premature failure.
9. 9

   Connect ball joint to knuckle
   Raise or lower the floor jack under the lower control arm to align the upper ball joint stud with the hole in the steering knuckle. Insert the ball joint stud through the knuckle and install the new castle nut. Tighten the nut to specification.
   Torque spec

   Ball Joint Nut115 Nm (85 lb-ft)
10. 10

    Install cotter pin
    Install a new cotter pin through the ball joint stud castle nut. If the slots do not align, tighten the nut further until the next slot aligns with the hole in the stud. Never loosen the nut to align the cotter pin. Bend the cotter pin ends to secure.
11. 11

    Install wheel and lower vehicle to ride height
    Reinstall the wheel and hand-tighten the lug nuts. Remove the jack stands and carefully lower the vehicle until the tires contact the ground but the full weight is not yet on the suspension. This simulates ride height for torquing the control arm bushings.
12. 12

    Torque control arm mounting bolts at ride height
    With the vehicle at ride height (tires on ground, suspension loaded but vehicle not fully lowered off jack), torque the front and rear upper control arm-to-frame bolts to specification. Use an 18mm wrench to prevent the nut from turning while torquing the bolt head with a torque wrench.
    ⚠This is the critical step to prevent bushing failure. Ensure suspension is at normal ride height before final torque.
    Torque spec

    Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
13. 13

    Final wheel installation
    Fully lower the vehicle to the ground and remove the floor jack. Torque the wheel lug nuts to specification in a star pattern to ensure even clamping force on the wheel.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify cotter pin is properly installed and bent on ball joint stud
3. Remove floor jack from under lower control arm
4. Double-check that control arm-to-frame bolts were torqued at ride height

Verification

• Visually inspect that upper control arm is properly seated in frame brackets
• Confirm ball joint stud is fully seated in knuckle with no gap
• Check that all fasteners are tight and cotter pin is secure
• Test drive vehicle at low speed and listen for unusual noises from suspension
• Have vehicle alignment checked and adjusted by qualified technician

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