This procedure covers the replacement of worn front lower control arm bushings on a 2021-2024 Ford F-150 with the 3.5L EcoBoost engine, requiring removal of the control arm assembly.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (2 bushings per arm) × 1 — Use OEM specification
• Ball joint cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack at manufacturer-specified jacking points
5. Support vehicle securely on jack stands placed under frame rails
6. Remove front wheel completely
7. Spray all fasteners with penetrating oil and allow to soak for 15-20 minutes

Procedure

1. 1

   Disconnect sway bar link
   Locate the sway bar link connection to the lower control arm. Hold the link shaft with an Allen key to prevent spinning, then remove the lower sway bar link nut using a 15mm wrench or socket. Swing the sway bar link up and out of the way.
   Torque spec

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

   Remove ball joint cotter pin
   Locate the ball joint castle nut where the lower control arm connects to the steering knuckle. Straighten and remove the cotter pin using pliers or a cotter pin removal tool. Discard the old cotter pin.
3. 3

   Loosen ball joint nut
   Using an 18mm socket, loosen the ball joint castle nut but do not remove it completely. Leave it threaded on a few turns to prevent the control arm from dropping suddenly when the taper breaks free.
4. 4

   Separate ball joint from knuckle
   Insert a ball joint separator tool or pickle fork between the control arm and steering knuckle. Strike the tool with a hammer to break the tapered ball joint free from the knuckle. Once the taper is broken, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠The control arm may drop suddenly when the ball joint separates. Keep hands and feet clear.
5. 5

   Support lower control arm
   Position a floor jack under the lower control arm to support its weight and maintain some tension on the bushings. Raise the jack just enough to slightly compress the suspension, making bolt removal easier.
6. 6

   Remove front control arm bolt
   Locate the front control arm mounting bolt at the frame. Using a 21mm socket and breaker bar, remove the front control arm bolt completely. Note the orientation of any washers or spacers for reinstallation.
7. 7

   Remove rear control arm bolt
   Using a 21mm socket and breaker bar, remove the rear control arm mounting bolt at the frame. Carefully lower the jack supporting the control arm and remove the control arm from the vehicle. Keep track of all washers and hardware.
8. 8

   Inspect control arm and ball joint
   With the control arm removed, thoroughly inspect the ball joint for wear, tears in the boot, or excessive play. Inspect the control arm body for cracks, bends, or damage. Replace the entire control arm if any damage is found beyond just the bushings.
9. 9

   Remove old bushings
   Using a hydraulic press or bushing removal tool kit, press out the old bushings from the control arm. Note the orientation of each bushing before removal. The bushings may require significant force to remove. Clean the bushing bores thoroughly with a wire brush to remove rust and debris.
   ⚠Use proper press adapters to avoid damaging the control arm. Ensure the control arm is properly supported during pressing operations.
10. 10

    Install new bushings
    Apply a light coat of silicone grease to the outer surface of the new bushings and the control arm bores. Using the hydraulic press or bushing installation tool, carefully press the new bushings into the control arm. Ensure bushings are oriented correctly and fully seated, flush with the control arm housing. The bushings should be centered in their bores.
11. 11

    Reinstall control arm to frame
    Position the control arm back into the frame mounts. Insert the front and rear control arm bolts through the bushings and frame brackets, but only hand-tighten the nuts at this stage. Do NOT torque these bolts yet - they must be torqued with vehicle weight on the wheels.
12. 12

    Reconnect ball joint to knuckle
    Use the floor jack to raise the outer end of the control arm until the ball joint stud aligns with the hole in the steering knuckle. Insert the ball joint stud into the knuckle and thread on the castle nut. Torque the ball joint castle nut to specification, then advance the nut as needed to align the next cotter pin hole (do not back off). Install a new cotter pin and bend the ends to secure.
    Torque spec

    Ball Joint Nut101 Nm (75 lb-ft)
13. 13

    Reconnect sway bar link
    Position the sway bar link back onto the lower control arm stud. Install the nut and torque to specification while holding the link shaft with an Allen key to prevent rotation.
    Torque spec

    Sway Bar Link71 Nm (52 lb-ft)
14. 14

    Reinstall wheel
    Clean the hub face and wheel mounting surface. Install the wheel and hand-tighten all lug nuts in a star pattern. Do not fully torque yet.
15. 15

    Lower vehicle and torque fasteners
    Carefully lower the vehicle until the wheels contact the ground but the jack stands are still supporting most of the weight. Remove the jack stands, then lower the vehicle completely so full weight is on the suspension. Rock the vehicle side-to-side several times to settle the suspension. Using a torque wrench, torque the control arm bolts to specification with the vehicle weight on the wheels. Finally, torque the wheel lug nuts to specification in a star pattern.
    ⚠Control arm bolts MUST be torqued with vehicle weight on wheels. This ensures proper bushing alignment and prevents premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification in the correct sequence
2. Verify new cotter pin is properly installed and secured on ball joint
3. Double-check that control arm bolts were torqued with vehicle weight on suspension

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering response and no vibrations
• After 50-100 miles, re-torque wheel lug nuts to specification
• Have a professional alignment performed within 100 miles, as bushing replacement will affect suspension geometry

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