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

Warnings

Tools required

Parts

• Lower control arm assembly × 1 — Use OEM specification or equivalent with ball joint pre-installed
• Ball joint castle nut (if not included with control arm) × 1 — Use OEM specification
• Cotter pin for ball joint nut × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid 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 with floor jack at manufacturer-specified lift point
5. Support vehicle securely on jack stands placed under frame rails
6. Remove wheel and tire assembly completely
7. Spray all control arm fasteners 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 suspension load. Raise jack until it just contacts the control arm but does not lift the vehicle. This prevents sudden dropping when fasteners are removed.
2. 2

   Disconnect sway bar link (if equipped)
   Locate the sway bar end link where it connects to the lower control arm. Hold the ball stud shaft with an Allen key to prevent spinning. Remove the nut securing the sway bar link to the control arm. Swing the link upward out of the way.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
3. 3

   Remove ball joint cotter pin and nut
   Remove the cotter pin from the ball joint castle nut by straightening the ends and pulling it out. Using an 18mm socket, remove the ball joint nut completely. Mark the orientation of the nut if it has a specific installation direction.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
4. 4

   Separate ball joint from steering knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the ball joint stud from the steering knuckle. Position the tool between the knuckle and control arm, and apply pressure to break the taper fit. Avoid damaging the ball joint boot. The control arm will drop slightly once separated.
   ⚠Ensure the floor jack is supporting the control arm before separation to prevent sudden drop and potential injury.
5. 5

   Remove front control arm mounting bolt
   Locate the front mounting bolt that secures the control arm to the front subframe. This bolt passes through the front bushing. Using a 19mm socket and breaker bar, remove the bolt completely. Note the position and any washers or spacers.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove rear control arm mounting bolt
   Locate the rear mounting bolt that secures the control arm to the rear subframe mounting point. Using a 19mm socket and breaker bar, remove this bolt completely. Note the position and any washers or spacers. The control arm should now be free.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
7. 7

   Remove lower control arm
   Lower the floor jack slightly and maneuver the control arm out of the vehicle. You may need to angle it to clear the steering knuckle and other suspension components. Inspect the mounting points on the subframe for damage or excessive wear.
8. 8

   Prepare new control arm and clean mounting surfaces
   Use a wire brush to clean the mounting bolt holes in the subframe and the ball joint taper seat in the steering knuckle. Remove any rust, dirt, or debris. Compare the new control arm to the old one to verify correct part. Check that ball joint boots are intact and bushings are properly seated.
9. 9

   Install new lower control arm
   Position the new control arm into place, aligning the front and rear bushing holes with the subframe mounting points. Use the floor jack to support the control arm at the correct height. Insert the front and rear mounting bolts through the bushings and subframe. Thread bolts by hand but do NOT torque at this time.
   ⚠Do not fully tighten control arm bolts yet. Final torque must be applied with vehicle weight on suspension.
10. 10

    Connect ball joint to steering knuckle
    Raise the floor jack to lift the control arm and insert the ball joint stud into the steering knuckle taper. Ensure the stud is fully seated in the taper. Install the new castle nut and tighten to specified torque. Align the castle nut slots with the hole in the stud and install a new cotter pin. Bend cotter pin ends to secure.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
11. 11

    Reconnect sway bar link
    Position the sway bar end link back into the mounting point on the lower control arm. Install the nut while holding the ball stud shaft with an Allen key to prevent spinning. Torque to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
12. 12

    Install wheel and lower vehicle
    Install the wheel and tire assembly. Thread lug nuts by hand to prevent cross-threading, then snug them in a star pattern. Lower the vehicle from jack stands until tires just contact the ground but most of the vehicle weight is still supported by the jack. Torque lug nuts to specification in a star pattern. Then fully lower vehicle to the ground and remove jack and stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
13. 13

    Final torque control arm bolts with weight on suspension
    With the vehicle now resting on the ground with full suspension load, crawl under the vehicle and torque the front and rear control arm mounting bolts to specification. This ensures the bushings are torqued in their normal operating position, preventing premature wear. Apply medium-strength thread locker if desired.
    ⚠This step is critical. Torquing control arm bolts without vehicle weight will cause bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify ball joint cotter pin is properly installed and bent
3. Confirm no tools or parts are left under the vehicle
4. Double-check lug nut torque after driving 50-100 miles

Verification

• Perform a visual inspection of all connections to ensure proper installation
• Test drive vehicle at low speed in a safe area and listen for unusual noises from the front suspension
• Check for proper steering response and verify no vibration or clunking sounds over bumps
• Schedule a professional alignment check as control arm replacement will affect alignment settings
• Inspect area under vehicle after first drive for any fluid leaks or loose fasteners

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