This procedure replaces the front coil springs on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, requiring strut disassembly and use of a spring compressor.

Warnings

Tools required

Parts

• Front coil spring (left) × 1 — Use OEM specification or heavy-duty aftermarket
• Front coil spring (right) × 1 — Use OEM specification or heavy-duty aftermarket
• Strut mount bearing (if worn) × 2 — Inspect during disassembly
• Strut mount nuts (upper) × 6 — Replace if corroded
• Cotter pin for ball joint × 2 — Use OEM specification
• Sway bar link (if damaged) × 2 — Inspect during removal

Preparation

1. Park vehicle on level, solid surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
3. Raise front of vehicle with floor jack at designated jacking points
4. Support vehicle securely on jack stands rated for weight, positioned under frame rails
5. Remove front wheels completely and set aside
6. Spray all suspension fasteners with penetrating oil and allow to soak 15-30 minutes
7. Photograph or diagram sway bar link orientation and strut positioning for reference during reassembly
8. Verify spring compressor tools are in good condition with no cracks, worn threads, or damaged hooks

Procedure

1. 1

   Disconnect sway bar link from strut
   Locate the sway bar link connecting to the strut assembly. Use an Allen key to hold the shaft while removing the upper nut with a wrench. If the link is seized or ball joint spins, use penetrating oil or carefully cut the nut off. Remove the link from the strut.
   Torque spec

   Sway Bar Link71 Nm (52 lb-ft)
2. 2

   Remove lower ball joint connection
   Locate the lower ball joint nut connecting the lower control arm to the steering knuckle. Remove the cotter pin and discard. Remove the ball joint castle nut completely. Use a ball joint separator tool or pickle fork to separate the ball joint taper from the knuckle. Do not strike the ball joint stud directly with a hammer.
   ⚠Using a pickle fork will likely damage the ball joint boot. Have replacement ball joints available if using this method.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
3. 3

   Remove strut lower mounting bolts
   Locate the two bolts securing the strut to the steering knuckle at the lower portion of the strut assembly. Support the knuckle and rotor assembly with a floor jack or have an assistant hold it. Remove both strut-to-knuckle bolts completely. Carefully separate the strut from the knuckle.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
4. 4

   Access and remove strut tower mounting nuts
   Open the hood and locate the strut tower under the hood near the fender. Remove any cowl covers or plastic trim if necessary to access the three upper strut mount nuts. Hold the strut assembly from below while removing all three nuts from the top. Carefully lower and remove the complete strut assembly from the vehicle.
   ⚠The strut assembly is heavy and awkward. Use proper lifting technique and have an assistant help if needed.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
5. 5

   Install spring compressor on strut
   Place the strut assembly in a strut vise or secure it firmly on a workbench. Install spring compressor tools on opposite sides of the coil spring (180 degrees apart), ensuring the hooks fully engage at least 3 coils. Verify both compressors are properly seated and threads are engaged correctly. This is a critical safety step.
   ⚠️Improperly installed spring compressors can slip during compression, causing the spring to violently release. Verify full engagement of hooks on at least 3 coils before proceeding.
6. 6

   Compress coil spring
   Alternately tighten each spring compressor gradually, going back and forth between them to compress the spring evenly. Continue until the spring tension is completely relieved from the upper strut mount (you should see a gap between the spring and mount). Verify the spring is stable and compressors are secure before proceeding.
   ⚠️Never compress one side completely before the other. Alternate between compressors to maintain even compression and prevent spring from binding or slipping.
7. 7

   Remove strut shaft nut and disassemble
   Hold the strut shaft with a wrench or Allen key (depending on design) to prevent rotation. Remove the upper strut shaft nut. Carefully remove the upper mount, bearing plate, and any washers or insulators, noting their order and orientation. Remove the compressed spring assembly with compressors still installed. Remove the lower spring isolator and bump stop from the strut shaft.
   ⚠Take photos or notes of the exact order and orientation of all components during disassembly for correct reassembly.
8. 8

   Transfer spring compressors to new spring
   Carefully and slowly release the spring compressors on the old spring in an alternating pattern until fully decompressed. Remove compressors from old spring. Install the same compressors on the new spring in the same positions (180 degrees apart). Compress the new spring using the same alternating technique until it is compressed to the same length as the old spring was during disassembly.
   ⚠️Ensure the new spring is compressed sufficiently that it will fit in the strut assembly without force. The spring must be free to rotate and position correctly during installation.
9. 9

   Reassemble strut with new spring
   Install the lower spring isolator and bump stop onto the strut shaft. Position the compressed new spring onto the strut, ensuring the lower end of the spring seats properly in the lower spring seat. Install any washers, bearing plate, and upper mount in the exact order removed. Align the spring end properly with the upper mount. Thread on and hand-tighten the upper strut shaft nut while holding the shaft to prevent rotation.
   ⚠Verify the spring ends are properly seated in both upper and lower spring seats before tightening the shaft nut.
10. 10

    Torque strut shaft nut and release spring
    Hold the strut shaft and torque the upper nut to specification (verify with service manual as this critical torque is not provided in database). Once the nut is properly torqued, slowly and alternately loosen both spring compressors in small increments. Verify the spring seats properly in both upper and lower perches as tension is released. Remove compressors completely once spring is fully decompressed.
    ⚠Watch the spring carefully as compressors are released to ensure it seats properly and does not slip or bind.
11. 11

    Install strut assembly into vehicle
    Lift the complete strut assembly into position in the wheel well. Align the upper mount studs with the holes in the strut tower. Have an assistant hold the strut in place or support from below while you install the three upper strut tower nuts from under the hood. Hand-tighten the nuts initially.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
12. 12

    Connect strut to knuckle
    Support the steering knuckle and align it with the strut lower mounting bracket. Insert both strut-to-knuckle bolts and install nuts. Torque both bolts to specification before proceeding.
    Torque spec

    Strut Bolts133 Nm (98 lb-ft)
13. 13

    Reconnect lower ball joint
    Position the lower control arm ball joint stud into the steering knuckle. Install the castle nut and torque to specification. Install a new cotter pin through the castle nut and ball joint stud, bending the ends to secure. Verify the cotter pin is properly installed and cannot back out.
    ⚠Always use a new cotter pin. Never reuse old cotter pins or substitute with wire or other fasteners.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
14. 14

    Reconnect sway bar link
    Install the sway bar link to the strut mounting point. Install the nut while holding the shaft with an Allen key to prevent rotation. Torque the nut to specification.
    Torque spec

    Sway Bar Link71 Nm (52 lb-ft)
15. 15

    Final torque and wheel installation
    Torque the three strut tower nuts to specification from under the hood. Install the wheel and thread on all lug nuts by hand. Lower the vehicle until the tire just touches the ground but most weight is still on jack stands. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands. Perform final torque verification on lug nuts in star pattern with full vehicle weight on ground.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Repeat entire procedure for opposite side, replacing the second coil spring
2. Reinstall any cowl covers or trim panels removed for strut tower access
3. If control arm bolts were removed, final-torque them with vehicle weight on wheels per specification
4. Clean any grease or fluid spills from components and underbody

Verification

• Verify all fasteners are torqued to specification, especially lug nuts, strut bolts, and ball joint nuts
• Confirm new cotter pins are installed and properly bent on both sides
• Check that wheels turn freely without rubbing or binding
• Bounce each corner of the vehicle and verify springs are seated properly with no unusual noises
• Test drive at low speed in a safe area, checking for abnormal noises, vibrations, or handling issues
• Have a professional alignment performed immediately - new springs will change ride height and alignment angles
• After 50-100 miles, re-torque all lug nuts and verify no suspension fasteners have loosened

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