This procedure covers the removal and replacement of the radius arm bushings on the front suspension of a 2021-2024 Ford F-150 3.5L EcoBoost RWD.

Warnings

Tools required

Parts

• Radius arm bushing kit × 2 — Use OEM specification
• Ball joint cotter pin × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove front wheels completely
6. Spray all suspension fasteners with penetrating oil and allow to soak for 15 minutes

Procedure

1. 1

   Remove wheel and access suspension
   With vehicle already raised and supported on jack stands, remove the front wheel completely. Inspect the radius arm and bushing area for corrosion or damage. Clean the area around fasteners with a wire brush if necessary.
2. 2

   Disconnect sway bar link
   Locate the sway bar link connection at the lower control arm. Hold the shaft with an Allen key to prevent spinning, then remove the sway bar link nut. Disconnect the sway bar link from the control arm and move it aside.
   Torque spec

   Sway Bar Link71 Nm (52 lb-ft)
3. 3

   Remove ball joint cotter pin and loosen nut
   Remove the cotter pin from the lower ball joint castle nut using pliers or a cotter pin puller. Loosen the ball joint nut but do not remove it completely yet. Leave the nut threaded on a few turns to protect the threads and prevent sudden separation.
4. 4

   Separate ball joint from knuckle
   Use a ball joint separator tool or pickle fork to separate the ball joint taper from the steering knuckle. Position the tool between the control arm and knuckle, then strike or tighten as appropriate for your tool type. Once the taper breaks free, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠Use caution when striking separation tools. Ensure proper eye protection and secure positioning to prevent tool slippage.
5. 5

   Support control arm
   Place a floor jack under the outer portion of the lower control arm to support its weight. This prevents the arm from dropping suddenly when the radius arm bolts are removed and makes reassembly easier.
6. 6

   Remove control arm mounting bolts
   Locate the control arm mounting bolts at the frame connection. Use a breaker bar if necessary to loosen these bolts. Remove both front and rear control arm bolts completely. Note the orientation and position of any washers or spacers for reinstallation.
   Torque spec

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

   Remove radius arm from vehicle
   With the control arm bolts removed and the arm supported by the jack, carefully lower the jack and guide the radius arm assembly out from the frame mounts. Remove the radius arm completely from the vehicle and place on a clean work surface.
8. 8

   Press out old bushings
   Using a hydraulic press and appropriate sized adapters, press the old bushings out of the radius arm. Position the arm in the press so the bushing has clearance to exit. Apply steady pressure until the bushing is completely removed. Inspect the bushing bore for damage, rust, or distortion. Clean the bore thoroughly with a wire brush and solvent.
   ⚠️Ensure radius arm is properly supported in press with adequate clearance. Improper setup can cause the arm to shift suddenly during pressing operations.
9. 9

   Install new bushings
   Apply a thin film of lubricant to the outer surface of the new bushings and the inside of the radius arm bore. Position the new bushing squarely at the opening of the bore. Using the hydraulic press with proper adapters, press the new bushing straight into the radius arm until it is fully seated and flush with the mounting surface. Verify the bushing is centered and seated evenly on both sides.
10. 10

    Reinstall radius arm to frame
    Position the radius arm back into the frame mounts. Use the floor jack to raise and align the control arm with the mounting holes. Insert the control arm bolts but do not torque them at this time. Thread the bolts in enough to hold the arm in position securely.
11. 11

    Reconnect ball joint to knuckle
    Raise the lower control arm with the floor jack until the ball joint stud aligns with the hole in the steering knuckle. Insert the ball joint stud through the knuckle and thread on the new castle nut. Tighten the nut to specification, then advance to the next castle slot if necessary to align the cotter pin hole. Install a new cotter pin and bend the ends to secure.
    Torque spec

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

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

    Sway Bar Link71 Nm (52 lb-ft)
13. 13

    Reinstall wheel
    Mount the wheel back onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground but the suspension is not yet loaded. Tighten lug nuts in a star pattern to specification using a torque wrench.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
14. 14

    Final torque control arm bolts with vehicle loaded
    Lower the vehicle completely to the ground so full vehicle weight is on the suspension. This is critical for proper bushing alignment. Torque the control arm mounting bolts to specification in this loaded position. Repeat the entire procedure for the opposite side if replacing both radius arm bushings.
    ℹ️Control arm bolts MUST be torqued with vehicle weight on wheels. Torquing in the air will cause premature bushing failure and handling issues.
    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 pins are properly installed and secured on ball joint castle nuts
3. Double-check that control arm bolts were torqued with vehicle weight on suspension
4. Perform the same procedure on the opposite side for balanced suspension performance

Verification

• Test drive the vehicle at low speed and verify no unusual noises or vibrations from front suspension
• Check for proper steering response and centering
• Inspect all fasteners for proper tightness after 50-100 miles of driving
• Schedule a professional wheel alignment after radius arm bushing replacement to ensure proper suspension geometry

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