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

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Ball joint castle nut (if not included with control arm) × 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, but do not remove
4. Raise front of vehicle with floor jack at designated lift point
5. Support vehicle on jack stands placed at frame rail support points
6. Remove wheel completely

Procedure

1. 1

   Inspect and document suspension position
   Before disassembly, photograph or mark the orientation of the upper control arm for reference during installation. Note the position of any shims if present (though 2015-2020 F-150s typically do not use shims).
2. 2

   Support lower control arm
   Position floor jack under the lower control arm to support the suspension and relieve tension on the upper control arm. Raise jack just enough to slightly compress the suspension, simulating ride height.
   ⚠The jack must remain under the lower control arm throughout the procedure to prevent the suspension from dropping and damaging brake lines or ABS sensors.
3. 3

   Remove upper ball joint nut
   Locate the ball joint castle nut where the upper control arm connects to the steering knuckle. Remove cotter pin if present. Using an 18mm socket, remove the ball joint nut completely. Apply penetrating oil if threads are corroded.
4. 4

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint stud from the steering knuckle. Insert the tool between the control arm and knuckle, then strike with a hammer or use the threaded separator mechanism. If using a pickle fork, be aware it may damage the ball joint boot. 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 make installation impossible.
5. 5

   Remove rear control arm bolt
   Locate the rear mounting bolt securing the upper control arm to the frame. This bolt passes through the rear bushing. Using a 15mm socket and breaker bar, remove the bolt completely. The bolt may be tight due to bushing compression.
6. 6

   Remove front control arm bolt
   Remove the front mounting bolt securing the upper control arm to the frame using a 15mm socket. Once removed, the control arm should be free to be removed from the vehicle. Note the orientation of any washers or spacers.
7. 7

   Remove upper control arm
   Carefully maneuver the upper control arm out of the wheel well. It may require slight rotation or angling to clear brake components and the frame. Inspect the mounting points on the frame for corrosion or damage.
8. 8

   Prepare new control arm and mounting points
   Clean the frame mounting points with a wire brush, removing any rust, debris, or old thread locker. Inspect the new control arm to ensure ball joint boot is intact and bushings are properly seated. Apply a thin coat of anti-seize to bolt threads if desired, but avoid getting any on bushing contact surfaces.
9. 9

   Install new upper control arm
   Position the new upper control arm into the frame mounts, aligning the bushings with the mounting holes. Insert both front and rear mounting bolts by hand, ensuring they thread properly. Do not tighten at this time. Thread the bolts through until they are snug but still allow the control arm to pivot.
10. 10

    Connect ball joint to knuckle
    Align the upper ball joint stud with the hole in the steering knuckle. You may need to use a pry bar to maneuver the knuckle into position or adjust the floor jack height under the lower control arm. Insert the ball joint stud fully into the knuckle until it seats.
11. 11

    Install and torque ball joint nut
    Thread the ball joint castle nut onto the ball joint stud by hand, then tighten to specification using an 18mm socket and torque wrench. If using a castle nut, align the cotter pin hole and install new cotter pin, bending ends to secure.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
12. 12

    Reinstall wheel
    Mount the wheel back onto the hub, threading lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern but do not torque yet. Remove jack stands and carefully lower vehicle until tires just touch the ground but vehicle weight is not fully on suspension.
13. 13

    Torque control arm bolts with weight on wheels
    With the vehicle lowered so the suspension is at normal ride height and weight is on the wheels, torque both the front and rear upper control arm mounting bolts to specification using a 15mm socket and torque wrench. This is critical for proper bushing alignment and longevity.
    ⚠Torquing control arm bolts with suspension hanging will cause bushing bind and premature failure. Ensure vehicle weight is on wheels.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
14. 14

    Final torque wheel lug nuts
    Completely lower vehicle to ground. Using a torque wrench and 21mm socket, torque all wheel lug nuts to specification in a star pattern to ensure even seating.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify ball joint castle nut cotter pin is properly installed and secured
3. Remove floor jack from under lower control arm
4. Double-check that no tools or parts were left in wheel well

Verification

• Bounce front end of vehicle several times to settle suspension and verify no unusual noises
• Visually inspect that upper control arm is properly seated in frame mounts with no gaps
• Verify ball joint connection is secure with no play
• Test drive vehicle at low speed in safe area to verify proper handling and listen for any suspension noises
• Schedule front end alignment as soon as possible, as removing the upper control arm will affect camber and caster settings

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