Torsion Bar

This procedure addresses torsion bar removal and replacement on 2021-2024 Ford F-150 RWD models. Note: The F-150 RWD uses coil spring front suspension, not torsion bars; this procedure assumes a misidentification and covers front coil spring strut replacement.

Warnings

Tools required

Parts

• Front strut assembly (complete) × 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
3. Raise front of vehicle with floor jack at manufacturer-recommended lift points
4. Support vehicle securely on jack stands placed under frame rails
5. Remove front wheels completely
6. Spray penetrating oil on all suspension fasteners and allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect sway bar end link
   Locate the sway bar end link connecting to the strut assembly. Use an Allen key to hold the shaft stationary while removing the upper nut with a wrench. Disconnect the end link from the strut.
   Torque spec

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

   Remove brake line bracket
   Locate the brake line bracket mounted to the strut body. Remove the mounting bolt securing the brake line bracket to the strut. Carefully move the brake line aside without kinking or stressing the line.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Mark strut-to-knuckle alignment
   Before removing any bolts, use a paint pen or marker to mark the alignment position of the strut relative to the steering knuckle. This will help maintain camber settings during reassembly.
4. 4

   Remove strut-to-knuckle bolts
   Remove the two bolts securing the strut to the steering knuckle. Support the knuckle assembly with your hand or a jack to prevent it from dropping. Separate the strut from the knuckle by pulling downward on the knuckle while keeping the strut in place.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
5. 5

   Access strut tower nuts
   Open the hood and locate the strut tower under the hood. Remove any plastic covers or cowl panels if necessary to access the top strut mounting nuts. There are typically three nuts visible at the top of each strut tower.
6. 6

   Remove strut tower nuts
   While supporting the strut assembly from below, remove the three nuts from the top strut mount. Carefully lower the strut assembly out of the fenderwell, guiding it past the brake components and control arms.
   ⚠The strut assembly is heavy. Have an assistant help support it or use a transmission jack to prevent dropping.
   Torque spec

   Strut Tower Nuts50 Nm (37 lb-ft)
7. 7

   Transfer components if necessary
   If installing a complete strut assembly, skip this step. If replacing only the strut cartridge, use a spring compressor to safely compress the coil spring, remove the top strut mount nut, and transfer the mount, spring, and isolators to the new strut. Follow spring compressor manufacturer instructions carefully.
   ⚠️Ensure spring compressor is properly engaged and tightened evenly on both sides before removing the strut shaft nut. An improperly compressed spring can cause catastrophic failure.
8. 8

   Install strut into strut tower
   Guide the new or rebuilt strut assembly up through the fenderwell and into the strut tower. Align the top mounting studs with the holes in the strut tower. Install the three strut tower nuts and hand-tighten only at this stage.
9. 9

   Connect strut to steering knuckle
   Raise the steering knuckle to meet the strut bracket. Align the strut-to-knuckle connection using the alignment marks made during disassembly. Insert the two strut-to-knuckle bolts and install nuts. Torque to specification.
   Torque spec

   Strut Bolts133 Nm (98 lb-ft)
10. 10

    Torque strut tower nuts
    Return to the engine bay and torque the three strut tower nuts to specification in a star pattern to ensure even loading on the strut mount.
    Torque spec

    Strut Tower Nuts50 Nm (37 lb-ft)
11. 11

    Reinstall brake line bracket
    Reattach the brake line bracket to the strut body. Ensure the brake line is properly positioned without any kinks or tension. Torque the mounting bolt to specification.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Reconnect sway bar end link
    Connect the sway bar end link to the strut assembly. Hold the shaft with an Allen key to prevent spinning and install the nut. Torque to specification.
    Torque spec

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

    Install wheels and lower vehicle
    Install the front wheels onto the hubs. Thread lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern but do not fully torque yet. Lower the vehicle until tires contact the ground but vehicle weight is not fully on the suspension. Final torque lug nuts in a star pattern to specification. Remove jack stands and lower vehicle completely.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Reinstall any cowl panels or plastic covers removed from the strut towers
2. Double-check all fasteners are torqued to specification
3. Verify brake lines have adequate clearance and are not rubbing against suspension components
4. Bounce each corner of the vehicle several times to settle the suspension

Verification

• Test drive the vehicle at low speed in a safe area and verify no unusual noises from the front suspension
• Check for proper steering response and verify vehicle tracks straight
• Inspect all fasteners for proper torque after test drive
• Schedule a professional alignment as soon as possible, as strut replacement affects camber and caster settings

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