This procedure covers removal and replacement of the upper control arm on the front suspension of a 2021-2024 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen wheel lug nuts on the side being serviced before lifting
4. Lift front of vehicle using floor jack at manufacturer-specified lift point
5. Support vehicle with jack stands under frame rails
6. Remove wheel completely

Procedure

1. 1

   Support lower control arm
   Position floor jack under the lower control arm near the ball joint to support the suspension load. Raise jack just enough to contact the control arm but not lift the vehicle. This prevents the suspension from dropping when the upper ball joint is disconnected.
2. 2

   Remove upper ball joint cotter pin
   Locate the upper ball joint where it connects to the steering knuckle. Use cotter pin pliers to straighten and remove the cotter pin from the ball joint castle nut. Discard the old cotter pin.
3. 3

   Remove ball joint nut
   Using appropriate socket, remove the castle nut from the upper ball joint stud. You may need to hold the stud with a wrench if it spins. Do not allow the nut to fall as it will be difficult to retrieve.
4. 4

   Separate ball joint from knuckle
   Insert ball joint separator tool between the upper control arm and steering knuckle. Apply steady pressure to separate the ball joint taper from the knuckle. If using a pickle fork, be aware this may damage the ball joint boot. A sharp tap with a hammer on the knuckle boss while applying upward pressure may help break the taper loose. Once separated, support the knuckle to prevent damage to brake lines or ABS wiring.
   ⚠The knuckle assembly will drop when the ball joint separates. Ensure brake lines and ABS sensor wires have adequate slack and will not be damaged.
5. 5

   Remove control arm mounting bolts
   Locate the two bolts securing the upper control arm to the frame mounting bracket. These are typically accessed from the front and rear of the control arm pivot points. Apply penetrating oil if needed. Use breaker bar to loosen, then remove both bolts completely. Note the orientation of any washers or spacers for reassembly.
6. 6

   Remove upper control arm
   Once both mounting bolts are removed, pull the upper control arm away from the frame bracket and out of the wheel well. Inspect the mounting area for corrosion or damage. Clean mounting surfaces with wire brush if necessary.
7. 7

   Install new upper control arm
   Position the new upper control arm into the frame mounting bracket. Insert both mounting bolts with any washers or spacers in their original orientation. Thread bolts by hand to ensure proper alignment. Do NOT torque these bolts yet - they must be torqued with vehicle weight on the wheels.
8. 8

   Connect ball joint to knuckle
   Align the upper ball joint stud with the hole in the steering knuckle. You may need to raise or lower the floor jack under the lower control arm to align the components. Insert the ball joint stud fully into the knuckle, ensuring it seats completely.
9. 9

   Install and torque ball joint nut
   Thread the castle nut onto the ball joint stud by hand until finger-tight. Using a torque wrench, tighten the nut to specification. Align the castle nut slots with the hole in the stud - you may need to tighten slightly beyond the torque spec to align, but never loosen to align. Install new cotter pin and bend ends to secure.
   Torque spec

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

    Install wheel and lower vehicle
    Reinstall the wheel onto the hub, threading lug nuts by hand. Lower the vehicle using the floor jack until the tire just contacts the ground but the full vehicle weight is not yet on the suspension. Torque wheel lug nuts to specification in a star pattern. Then lower vehicle completely so full weight is on the wheels.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
11. 11

    Torque control arm mounting bolts
    With the vehicle weight fully on the wheels and suspension at normal ride height, torque both upper control arm mounting bolts to specification. This is critical - torquing these bolts with the suspension hanging will cause premature bushing failure. If you cannot access the bolts with the vehicle on the ground, you may need to drive the vehicle forward a few feet to rotate the bolts to an accessible position.
    ⚠Control arm mounting bolts MUST be torqued at normal ride height with vehicle weight on wheels. Failure to do so will cause premature bushing wear and failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Ensure new cotter pin is properly installed and bent to prevent backing out
2. Verify all fasteners are tightened to specification
3. Remove floor jack and jack stands
4. Perform final torque check on wheel lug nuts after lowering vehicle

Verification

• Test drive vehicle at low speed and verify no unusual noises or handling issues
• Check for proper steering response and no pulling to either side
• Visually inspect ball joint connection and control arm mounting bolts for proper installation
• Schedule front end alignment as replacing the upper control arm will alter suspension geometry and camber settings

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