This procedure covers the replacement of the front lower control arm bushings on a 2015 Kia Forte with 1.8L I4 engine, requiring removal of the control arm from the vehicle.

Warnings

Tools required

Parts

• Front lower control arm bushing kit (front) × 1 — Use OEM specification
• Front lower control arm bushing kit (rear) × 1 — Use OEM specification
• Cotter pin for ball joint × 1 — 3mm x 30mm

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 (do not remove)
4. Raise front of vehicle with floor jack at designated lift point
5. Support vehicle securely on jack stands under the front subframe
6. Remove front wheel completely
7. Spray all fasteners with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Disconnect sway bar link (if necessary for access)
   If sway bar link interferes with control arm removal, hold the link shaft with a 6mm Allen key and remove the lower nut using a 14mm wrench. The link can be left attached at top and swung aside.
   Torque spec

   Sway Bar Link Nuts55 Nm (41 lb-ft)
2. 2

   Remove ball joint cotter pin
   Locate the ball joint castle nut at the outer end of the control arm where it connects to the steering knuckle. Straighten and remove the cotter pin using cotter pin pliers. Discard the old cotter pin.
   ℹ️If cotter pin is corroded, it may break during removal. Ensure complete removal of all fragments.
3. 3

   Loosen ball joint nut
   Using an 18mm socket, loosen the ball joint castle nut but do not remove it completely yet. Leave the nut threaded on 2-3 turns to protect the threads and prevent sudden separation.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
4. 4

   Separate ball joint from knuckle
   Insert a ball joint separator tool or pickle fork between the control arm and steering knuckle at the ball joint taper. Strike the tool firmly to break the taper fit. Once separated, remove the castle nut completely and lower the control arm away from the knuckle.
   ⚠The control arm may drop suddenly when the ball joint releases. Keep hands clear of pinch points.
5. 5

   Remove front control arm mounting bolt
   Locate the front control arm mounting bolt that connects to the front subframe. This is the forward mounting point. Use a 19mm socket and breaker bar to remove the bolt completely. Support the control arm to prevent it from falling.
   Torque spec

   Control Arm Bolts165 Nm (122 lb-ft)
6. 6

   Remove rear control arm mounting bolt
   Locate the rear control arm mounting bolt at the rearward connection to the subframe. Use a 19mm socket and breaker bar to remove this bolt completely. The control arm can now be removed from the vehicle.
   Torque spec

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

   Remove control arm from vehicle
   Carefully maneuver the control arm out of the wheel well. Note the orientation and position of any washers or spacers for proper reinstallation. Clean the control arm mounting areas on the subframe with a wire brush.
   ℹ️Take photos of the control arm orientation and any spacer positions before removal for reference during installation.
8. 8

   Press out old bushings
   Using a hydraulic press or control arm bushing press tool kit, press out the old front and rear bushings from the control arm. Apply force evenly and ensure the receiving cup is properly sized. Note the orientation of the bushings, particularly any offset or alignment marks.
   ⚠Ensure press is properly aligned to avoid damaging the control arm. Bushings are interference fit and require significant force.
9. 9

   Install new bushings
   Clean the bushing bores in the control arm thoroughly. Apply a light coating of dish soap or bushing lubricant to the outer sleeve of the new bushings (never use petroleum-based lubricants). Using the hydraulic press, press the new bushings into the control arm until fully seated. Ensure bushings are aligned correctly with any orientation marks matching OEM specifications.
   ⚠Do not use grease or oil on bushings as this can cause them to slip out of position. Use only soap-based lubricant.
10. 10

    Install control arm to subframe
    Position the control arm back into the vehicle, aligning the bushings with the mounting points on the subframe. Insert both front and rear mounting bolts but do not tighten them yet. Thread bolts in by hand to ensure proper alignment. Bolts should be snug but not torqued at this stage.
    ⚠Do NOT torque control arm bolts at this time. They must be torqued with vehicle weight on suspension.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)
11. 11

    Connect ball joint to knuckle
    Lift the outer end of the control arm and align the ball joint stud with the hole in the steering knuckle. Insert the stud through the knuckle and thread on the castle nut. Use a pry bar if needed to align the holes. Torque the castle nut to specification.
    Torque spec

    Ball Joint Nut84 Nm (62 lb-ft)
12. 12

    Install new cotter pin
    Align the castle nut slots with the hole in the ball joint stud. If slots do not align, tighten the nut slightly (never loosen) until alignment is achieved. Insert a new cotter pin through the hole and bend the ends to secure it properly.
    ℹ️Castle nut slots must align with stud hole. If needed, tighten nut up to 1/6 turn additional, but never back it off.
13. 13

    Reconnect sway bar link (if removed)
    If the sway bar link was disconnected, position it back to the control arm or strut mounting point. Hold the shaft with a 6mm Allen key and tighten the nut to specification using a 14mm wrench.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
14. 14

    Install wheel and lower vehicle
    Reinstall the wheel and thread lug nuts by hand. Lower the vehicle from jack stands until the tire just contacts the ground but suspension is not fully loaded. Torque lug nuts in a star pattern to specification. Then lower vehicle completely so full weight is on suspension.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)
15. 15

    Torque control arm bolts with weight on suspension
    With the vehicle on the ground and full weight on the suspension, torque both front and rear control arm bolts to specification. This is critical for proper bushing life. Access may require turning the steering wheel or using a long extension. Torque in final specification with vehicle at normal ride height.
    ⚠This step is critical. Torquing control arm bolts while suspension is hanging will preload the bushings and cause premature failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Repeat procedure for opposite side if replacing both sides
2. After both sides are complete, check that all fasteners are properly torqued
3. Verify cotter pins are properly installed and secured on both sides

Verification

• Test drive vehicle at low speed and verify no clunking or rattling noises from front suspension
• Perform a visual inspection under the vehicle to confirm all bolts are tight and cotter pins are secure
• Have front end alignment checked and adjusted as control arm removal will affect toe settings
• After 50-100 miles, re-check control arm bolt torque and cotter pin security

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