This procedure covers removal and replacement of the rear upper control arm on a 2015-2020 Ford F-150 with 5.0L V8 engine, including proper torque sequencing and alignment considerations.

Warnings

Tools required

Parts

• Rear upper control arm assembly × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — 3/32 inch diameter

Preparation

1. Park vehicle on level ground and engage parking brake
2. Chock front wheels securely
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and support frame with jack stands on both sides
5. Remove rear wheel on affected side
6. Spray control arm bolts and ball joint nut with penetrating oil if corrosion is present

Procedure

1. 1

   Support the rear axle
   Position a floor jack under the rear axle housing near the control arm mounting point. Raise jack until it just contacts the axle and provides light support. This prevents the axle from dropping when the control arm is disconnected and maintains suspension geometry during removal.
2. 2

   Remove ball joint cotter pin
   Locate the upper control arm ball joint where it connects to the rear knuckle assembly. Use cotter pin pliers to straighten and remove the cotter pin from the ball joint castle nut. Discard the old cotter pin.
3. 3

   Remove ball joint nut
   Using an 18mm socket, remove the ball joint castle nut from the upper control arm ball joint stud. Keep the nut for reference when installing the new control arm. The ball joint taper will likely still be seated in the knuckle at this point.
4. 4

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to break the taper fit between the ball joint stud and knuckle. Position the separator between the control arm and knuckle, then strike or tighten (depending on tool type) until the ball joint releases. The control arm will drop away from the knuckle once separated.
   ⚠Do not strike the knuckle or control arm directly with a hammer as this can damage components. Use proper ball joint separation tools.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the frame bracket. Using a 19mm socket and breaker bar, remove the bolt completely. Note the orientation of any washers or spacers for reinstallation. The control arm will now be supported only by the rear mounting bolt.
6. 6

   Remove rear control arm mounting bolt
   Using a 19mm socket and breaker bar, remove the rear mounting bolt that secures the control arm to the frame bracket. Support the control arm as you remove the final bolt to prevent it from falling. Remove the control arm from the vehicle and note the orientation of bushings and any spacers.
7. 7

   Clean mounting surfaces
   Use a wire brush to clean the frame mounting brackets and knuckle ball joint taper seat. Remove any rust, debris, or old thread locker from bolt holes. Inspect frame mounting points for cracks or damage. Clean the ball joint stud threads on the new control arm.
8. 8

   Install new control arm
   Position the new upper control arm into the frame brackets, aligning the bushings with the mounting holes. Insert both front and rear mounting bolts by hand, ensuring any spacers or washers are in their correct positions. Thread bolts several turns but do not tighten at this time. The bolts will be torqued later with vehicle weight on the suspension.
9. 9

   Connect ball joint to knuckle
   Raise the control arm ball joint stud into the tapered hole in the rear knuckle. You may need to use the floor jack to adjust axle height slightly to align the components. Thread the new castle nut onto the ball joint stud by hand, ensuring it threads smoothly without cross-threading.
   Torque spec

   Ball Joint Nut110 Nm (81 lb-ft)
10. 10

    Torque ball joint nut and install cotter pin
    Torque the ball joint castle nut to specification. The castle nut slots must align with the cotter pin hole in the stud. If slots do not align, tighten the nut further (never loosen) until the next slot aligns with the hole. Insert a new cotter pin through the hole and bend the ends to secure it.
    ⚠Never loosen a castle nut to align cotter pin holes. Always tighten to the next slot alignment.
    Torque spec

    Ball Joint Nut110 Nm (81 lb-ft)
11. 11

    Reinstall wheel
    Mount the rear wheel onto the hub and thread all lug nuts by hand. Use a torque wrench to tighten lug nuts to specification in a star pattern. Lower the vehicle until the tire just touches the ground but the suspension is not fully loaded yet.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)
12. 12

    Final torque control arm bolts at ride height
    With the vehicle lowered so full weight is on the suspension (tires on ground, jack stands still supporting frame for safety), torque both the front and rear control arm mounting bolts to specification. This critical step ensures bushings are not pre-loaded and will have maximum service life. Remove jack stands and lower vehicle completely.
    ⚠Failure to torque control arm bolts at ride height will cause premature bushing failure and poor handling.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification
2. Ensure cotter pin is properly installed and bent
3. Remove floor jack from under axle
4. Double-check wheel lug nuts are torqued in star pattern

Verification

• Bounce the rear of the vehicle several times to settle the suspension and verify no unusual noises
• Visually inspect that control arm is properly seated in frame brackets with no gaps
• Confirm ball joint cotter pin is secure and nut shows no movement
• Test drive at low speed to verify no clunking or handling issues
• Schedule four-wheel alignment immediately as camber and toe will be out of specification

More procedures for this vehicle