This procedure covers the removal and replacement of the front upper control arm on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including ball joint separation and proper torque procedures at ride height.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM Ford part or equivalent Moog/Motorcraft
• Ball joint nut (if not included with control arm) × 1 — Use OEM specification
• Control arm mounting hardware kit (if reuse not recommended) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove wheel and tire assembly completely
6. Spray all control arm bolts and ball joint nut with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Support the lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the weight of the knuckle and prevent the assembly from dropping when the upper ball joint is separated. Apply just enough pressure to support the assembly without compressing the suspension.
2. 2

   Remove the upper ball joint nut
   Using a 21mm socket, remove the upper ball joint castle nut from the top of the steering knuckle. Remove the cotter pin if present. Keep the nut accessible as you may need to thread it back on partially during separation to protect the threads.
   Torque spec

   Ball Joint Nut115 Nm (85 lb-ft)
3. 3

   Separate the ball joint from the knuckle
   Insert a ball joint separator tool between the upper control arm and the top of the steering knuckle. Apply force to break the taper connection. Alternatively, use a pickle fork, but be aware this may damage the ball joint boot if reusing the control arm. Once separated, thread the nut back on a few turns to prevent the knuckle from falling.
   ⚠The knuckle assembly will shift when the ball joint separates. Ensure the floor jack is supporting the lower control arm securely.
4. 4

   Remove the upper control arm-to-frame bolts
   Locate the two horizontal bolts securing the upper control arm to the frame mounts. These are typically 19mm head bolts. Remove the rear bolt first, then the front bolt. The control arm will now be free to remove. Note the position and orientation of any washers or alignment shims for reinstallation.
   ℹ️Some vehicles may have alignment shims between the control arm and frame. Mark their position or photograph before removal for proper reinstallation.
   Torque spec

   Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
5. 5

   Remove the upper control arm
   Carefully maneuver the upper control arm out of the frame mounts and away from the vehicle. The ball joint stud will slide out of the knuckle as you remove the assembly. Inspect the frame mounting points for corrosion or damage. Clean the mounting surfaces with a wire brush if necessary.
6. 6

   Prepare and install the new upper control arm
   Compare the new upper control arm to the old unit to verify correct replacement. Clean the frame mounting surfaces thoroughly. Install any alignment shims in their original positions. Position the new control arm into the frame mounts and start both bolts by hand. Do NOT fully tighten at this time - bolts must be torqued at ride height.
7. 7

   Connect the ball joint to the knuckle
   Align the ball joint stud with the hole in the top of the steering knuckle. You may need to use the floor jack to raise or lower the knuckle slightly for alignment. Once the stud is through the knuckle, install the new castle nut and tighten by hand. Ensure the threads engage smoothly.
8. 8

   Torque the ball joint nut
   Using a torque wrench and 21mm socket, torque the upper ball joint nut to 115 Nm (85 lb-ft). If using a castle nut with cotter pin, tighten to specification then advance to the next castle slot if needed for cotter pin alignment. Do not back off to align. Install new cotter pin and bend ends to secure.
   Torque spec

   Ball Joint Nut115 Nm (85 lb-ft)
9. 9

   Reinstall wheel and lower vehicle to ride height
   Install the wheel and tire assembly. Thread lug nuts by hand to prevent cross-threading, then snug with a wrench (do not torque yet). Carefully lower the vehicle until the suspension is at normal ride height with the full weight of the vehicle on the wheels, but keep the jack stands in place for safety. The suspension must be at ride height before final torquing of control arm frame bolts.
10. 10

    Torque control arm-to-frame bolts at ride height
    With the vehicle at ride height (full weight on suspension), torque both upper control arm-to-frame bolts to 150 Nm (111 lb-ft) using a 19mm socket and torque wrench. Torque the front bolt first, then the rear bolt. This is critical - torquing at full droop will preload the bushings incorrectly and cause premature failure.
    ⚠Failure to torque these bolts at ride height will result in premature bushing failure and poor handling. Verify suspension is loaded before final torque.
    Torque spec

    Control Arm-to-Frame Bolts150 Nm (111 lb-ft)
11. 11

    Final wheel installation
    Raise the vehicle slightly, remove jack stands, and lower vehicle completely to the ground. Torque all wheel lug nuts to 156 Nm (115 lb-ft) in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification, particularly the control arm-to-frame bolts at ride height
2. Verify the ball joint cotter pin is properly installed and secured if applicable
3. Check that no tools or parts were left in the wheel well or suspension area

Verification

• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Perform a visual inspection to confirm all bolts are tight and properly seated
• Schedule a professional wheel alignment within 50 miles - upper control arm replacement will affect camber and caster settings
• After 50-100 miles, re-check torque on all suspension fasteners including ball joint nut and control arm bolts

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