Replace the rear control arm bushings on a 2021-2024 Ford F-150 3.5L EcoBoost by removing the control arm assembly, pressing out old bushings, installing new ones, and reinstalling with proper torque specifications.

Warnings

Tools required

Parts

• Rear control arm bushing set (upper or lower as needed) × 2 — Use OEM specification
• Cotter pin (if ball joint is disconnected) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
4. Raise rear of vehicle with floor jack and support securely on jack stands under frame rails
5. Remove rear wheels completely
6. Spray all control arm fasteners with penetrating lubricant and allow to soak 10-15 minutes

Procedure

1. 1

   Disconnect sway bar link if necessary
   If the sway bar link interferes with control arm removal, disconnect it from the control arm. Hold the shaft with an Allen key while loosening the nut to prevent spinning. Only disconnect the lower end attached to the control arm.
   Torque spec

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

   Disconnect ball joint from knuckle
   Remove the ball joint nut securing the control arm to the rear knuckle. Use a ball joint separator or pickle fork to break the taper connection between the ball joint stud and knuckle. Apply force gradually and be prepared for sudden release. Discard the old cotter pin if present.
   ⚠Ball joint taper may release suddenly. Keep hands clear of pinch points.
   Torque spec

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

   Support suspension and knuckle
   Use a floor jack or jack stand to support the rear knuckle assembly to prevent it from dropping when the control arm is removed. Position support under the knuckle or axle housing to maintain approximate ride height position.
4. 4

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that secure the control arm to the frame/subframe. These are typically at the front and rear of the control arm. Use a breaker bar if necessary to loosen these bolts. Remove both bolts completely and note their orientation and any spacers or washers.
   ℹ️Take photos of control arm orientation and hardware position before removal for reference during reinstallation.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
5. 5

   Remove control arm from vehicle
   With all fasteners removed, maneuver the control arm out of the suspension. You may need to rotate or angle it to clear the knuckle, frame brackets, and any brake or sensor lines. Inspect the control arm for damage or excessive wear.
6. 6

   Press out old bushings
   Using a hydraulic press or control arm bushing press kit, press the old bushings out of the control arm. Support the control arm properly on the press bed and ensure the pressing direction is aligned with the bushing bore. Apply steady pressure until bushings are fully removed. Clean the bushing bores thoroughly with a wire brush and inspect for damage.
   ⚠Wear safety glasses during pressing operations. Bushings may eject with force.
7. 7

   Install new bushings
   Apply a light coating of dish soap or bushing lubricant (not petroleum-based) to the outer sleeve of the new bushings to aid installation. Position the new bushing in the control arm bore with correct orientation (note any offset or alignment marks). Using the press, carefully drive the bushing into the bore until it is fully seated and flush with the control arm housing. Ensure bushing is not cocked or binding during installation.
   ℹ️Many bushings have directional orientation or voids that must align with suspension travel. Verify correct orientation before pressing.
8. 8

   Reinstall control arm to frame
   Position the control arm back into the mounting brackets on the frame/subframe. Insert the mounting bolts finger-tight only. Ensure any spacers or washers are in their original positions. Do not torque these bolts yet - they must be torqued with vehicle weight on the suspension.
9. 9

   Reconnect ball joint to knuckle
   Align the control arm ball joint stud with the hole in the knuckle. You may need to use a pry bar or adjust the jack under the knuckle to align the holes. Install the ball joint nut and tighten to specification. Install a new cotter pin through the castellated nut and ball joint stud, then bend the ends of the cotter pin to secure.
   ℹ️If cotter pin holes do not align after torquing, tighten nut further (never loosen) until next slot aligns with hole.
   Torque spec

   Ball Joint Nut101 Nm (75 lb-ft)
10. 10

    Reconnect sway bar link if removed
    If the sway bar link was disconnected in step 1, reconnect it to the control arm. Hold the shaft with an Allen key while torquing the nut to prevent spinning.
    Torque spec

    Sway Bar Link71 Nm (52 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Install the rear wheel and hand-tighten lug nuts in a star pattern. Lower the vehicle until the tires just contact the ground but jack stands are still supporting most of the weight. This positions the suspension at ride height.
12. 12

    Torque control arm bolts at ride height
    With the vehicle weight on the wheels (tires touching ground), torque the control arm mounting bolts to specification. This is critical - torquing these bolts with the suspension hanging will preload the bushings and cause premature failure. After torquing, fully lower vehicle off jack stands.
    ⚠Control arm bolts MUST be torqued with vehicle weight on suspension. Failure to do so will destroy new bushings.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
13. 13

    Torque wheel lug nuts
    With vehicle fully on the ground, torque the wheel lug nuts to specification in a star pattern to ensure even seating of the wheel.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Repeat entire procedure for opposite side if replacing both sides
2. Verify all fasteners are properly torqued and cotter pins are installed
3. Check that no tools or parts were left in wheel wells or under vehicle

Verification

• Test drive vehicle at low speed and verify no unusual noises from rear suspension
• Check for proper alignment - vehicle should track straight without pulling
• Perform visual inspection under vehicle after test drive to confirm no fasteners have loosened
• Schedule a professional wheel alignment if vehicle pulls or steering wheel is off-center, as bushing replacement affects alignment angles

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