This procedure covers replacement of the front upper control arm bushings on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 RWD by removing the upper control arm assembly.

Warnings

Tools required

Parts

• Front upper control arm bushing kit × 2 — Use OEM specification
• Cotter pin × 2 — Use OEM specification

Preparation

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

Procedure

1. 1

   Support lower control arm
   Position a floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack just enough to lightly compress the coil spring and take load off the upper control arm. This prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Remove upper ball joint cotter pin and nut
   Locate the upper ball joint at the steering knuckle. Remove and discard the cotter pin using pliers or side cutters. Using an 18mm socket, remove the ball joint castle nut completely. Note the nut orientation and depth for reassembly.
3. 3

   Separate upper ball joint from knuckle
   Using a ball joint separator tool or pickle fork, separate the upper ball joint stud from the steering knuckle. Position the tool between the control arm and knuckle, then strike with a hammer or tighten the separator tool until the taper breaks free. The knuckle will drop slightly when separated. Be prepared to support the knuckle assembly.
   ⚠Ball joint separator can cause sudden release. Keep hands and face clear of impact area.
4. 4

   Remove front control arm bolt
   Locate the front mounting bolt of the upper control arm at the frame bracket. This bolt runs horizontally through the front bushing. Using an 18mm socket and wrench, remove the bolt completely while supporting the control arm. The arm may shift when the bolt is removed.
5. 5

   Remove rear control arm bolt
   Locate the rear mounting bolt of the upper control arm at the frame bracket. Using an 18mm socket and wrench, remove this bolt completely. Support the control arm as it will now be free to remove. Lower the control arm away from the frame and out of the vehicle.
6. 6

   Inspect and clean control arm
   Inspect the control arm for any damage, cracks, or excessive wear beyond the bushings. Clean the bushing bores thoroughly with a wire brush, removing all rust, dirt, and old bushing remnants. Inspect the ball joint for play or damage; if worn, consider replacing the entire control arm assembly.
7. 7

   Press out old bushings
   Using a hydraulic press or control arm bushing removal tool, press out the old bushings from the control arm. Support the control arm on the press bed with the bushing positioned over an opening. Apply steady pressure to drive the bushing out. If using a bushing tool kit, select the appropriate receiver and driver sizes for the Ford F-150 upper control arm bushings. Remove both front and rear bushings.
   ⚠Bushings may release suddenly when pressed out. Wear safety glasses and keep hands clear of press area.
8. 8

   Press in new bushings
   Clean the bushing bores one final time. Apply a light coat of dish soap or approved lubricant to the outer sleeve of the new bushings (never use petroleum-based products). Position the new bushing in the control arm bore, ensuring proper orientation if bushings have directional markings. Using the hydraulic press or bushing installation tool, press the new bushing in until it is fully seated and flush with the control arm housing. The bushing should be centered in the bore. Repeat for both front and rear bushings.
9. 9

   Install control arm to frame
   Position the control arm with new bushings into the frame bracket mounting points. Insert the front and rear control arm bolts through the frame brackets and bushing sleeves. Thread the bolts by hand to ensure proper alignment. Do NOT fully tighten at this time - snug only. The bolts must be torqued with vehicle weight on the suspension.
10. 10

    Connect ball joint to knuckle
    Raise the floor jack under the lower control arm to lift the steering knuckle into position. Align the upper ball joint stud with the hole in the top of the knuckle. Insert the ball joint stud through the knuckle until it extends far enough for the castle nut. Thread the castle nut onto the ball joint stud by hand, ensuring threads are clean and engage properly.
11. 11

    Torque ball joint nut and install cotter pin
    Using a torque wrench and 18mm socket, torque the ball joint castle nut to 101 Nm (75 lb-ft). If the castle nut slots do not align with the cotter pin hole in the stud, tighten the nut additionally (never loosen) until the next slot aligns. Insert a new cotter pin through the stud hole and bend the ends to secure. Verify the cotter pin is fully seated and properly bent to prevent loosening.
    Torque spec

    Ball Joint Nut102 Nm (75 lb-ft)
12. 12

    Install wheel and lower vehicle
    Install the wheel onto the hub, threading lug nuts by hand to start. Tighten lug nuts in a star pattern using a torque wrench to 156 Nm (115 lb-ft). Repeat for opposite side if both control arm bushings were replaced. Carefully lower the vehicle until the tires contact the ground but the suspension is still slightly unloaded. Remove jack stands.
    Torque spec

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

    Final torque control arm bolts with vehicle loaded
    With the vehicle fully lowered and weight on all four wheels, locate the front and rear upper control arm mounting bolts from above or below the vehicle. Using a torque wrench with 18mm socket, torque both control arm bolts to 165 Nm (122 lb-ft). This must be done with the suspension at normal ride height to prevent bushing bind and premature wear.
    ℹ️Control arm bolts MUST be torqued at normal ride height. Torquing with suspension hanging will cause premature 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 new cotter pin is properly installed and secured at ball joint
3. Double-check wheel lug nuts are torqued in star pattern to 156 Nm (115 lb-ft)
4. Repeat entire procedure for opposite side if replacing both upper control arm bushings

Verification

• Test drive vehicle at low speed and verify no clunking or unusual noises from front suspension
• Perform visual inspection under vehicle to confirm all fasteners are tight and cotter pin is secure
• Check steering response - there should be no looseness or wandering
• Schedule a professional wheel alignment as suspension geometry has been altered. Alignment is mandatory after this repair to prevent tire wear and handling issues

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