This procedure covers removal and replacement of the front upper control arm bushings on a 2015 Kia Forte with 1.8L I4 engine, requiring partial disassembly of the front suspension.

Warnings

Tools required

Parts

• Front upper control arm bushing kit × 2 — Use OEM specification or aftermarket equivalent
• 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 manufacturer-specified jacking points
5. Remove both front wheels
6. Spray all suspension fasteners with penetrating lubricant and allow to soak for 10-15 minutes

Procedure

1. 1

   Remove ball joint cotter pin and nut
   Locate the upper control arm ball joint at the steering knuckle. Use cotter pin puller to remove and discard the cotter pin from the ball joint castle nut. Using a 19mm socket, remove the ball joint nut completely. Keep nut for torque reference.
2. 2

   Separate ball joint from knuckle
   Install ball joint separator tool between the upper control arm and steering knuckle. Tighten the tool to apply pressure, then strike the knuckle boss area with a hammer to shock the taper loose. Once separated, remove the separator tool and support the knuckle to prevent strain on the lower ball joint and brake lines.
   ⚠Do not strike the ball joint stud directly as this can damage the threads. Strike only the knuckle casting.
3. 3

   Disconnect sway bar link if necessary
   If the sway bar link interferes with control arm removal, use an Allen key to hold the ball stud shaft and remove the upper sway bar link nut with an 18mm wrench. Disconnect the link from the control arm.
4. 4

   Remove control arm mounting bolts
   Locate the front and rear control arm mounting bolts connecting the control arm to the subframe or body. These are typically 17-19mm bolts. Use a breaker bar to loosen both bolts, then remove them completely. Note the orientation and position of any washers or alignment shims for reinstallation.
   ⚠Control arm may drop suddenly when final bolt is removed. Support the arm before removing the second bolt.
5. 5

   Remove control arm from vehicle
   With both mounting bolts removed and ball joint disconnected, carefully remove the upper control arm from the vehicle. Place it on a clean work surface for bushing replacement. Inspect the control arm for cracks, bends, or damage. Replace the arm if any damage is found.
6. 6

   Press out old bushings
   Using a hydraulic press and appropriate bushing removal tool or socket, press the old bushings out of the control arm. Apply steady pressure until the bushing releases from the bore. Clean the bushing bore thoroughly with a wire brush and inspect for damage or deformation. If the bore is damaged, the control arm must be replaced.
   ⚠Ensure press tools are properly aligned to avoid damaging the control arm bore. Misalignment can bend or crack the control arm.
7. 7

   Install new bushings
   Apply a light coat of dish soap or approved bushing lubricant to the outer diameter of the new bushing. Align the bushing properly in the control arm bore, ensuring any orientation marks or voids are positioned correctly per service manual specifications. Using the hydraulic press and proper installation tool, press the new bushing into the control arm until fully seated and flush with the bore.
8. 8

   Reinstall control arm to vehicle
   Position the control arm back into the mounting location. Insert both control arm mounting bolts with any washers or shims in their original positions. Thread the bolts by hand but DO NOT torque at this time - they must be torqued with vehicle weight on the suspension. Leave bolts snug but not fully tightened.
9. 9

   Reconnect ball joint to knuckle
   Align the upper control arm ball joint stud with the hole in the steering knuckle. You may need to use a pry bar or jack to align the components. Install the ball joint nut and tighten to specification. Install a new cotter pin through the castle nut and ball joint stud. Bend the cotter pin tabs to secure.
   ℹ️If the cotter pin holes do not align after torquing, tighten the nut further until the next slot aligns. Never loosen the nut to align the cotter pin hole.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
10. 10

    Reconnect sway bar link if removed
    If the sway bar link was disconnected, reconnect it to the control arm. Hold the ball stud shaft with an Allen key and tighten the nut to specification.
    Torque spec

    Sway Bar Link Nuts55 Nm (41 lb-ft)
11. 11

    Reinstall wheels
    Install the front wheels and hand-tighten the lug nuts in a star pattern. Do not torque lug nuts yet as the vehicle must be lowered first.
12. 12

    Lower vehicle and torque fasteners
    Carefully lower the vehicle until the suspension is at normal ride height with full weight on the wheels, but keep the jack slightly engaged for safety. Torque the control arm mounting bolts to specification - this MUST be done with vehicle weight on the suspension to properly preload the bushings. After control arm bolts are torqued, fully lower the vehicle and remove jack stands. Torque wheel lug nuts in a star pattern to specification.
    ⚠Control arm bolts MUST be torqued at normal ride height. Torquing with suspension hanging will cause premature bushing failure and poor handling.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. Repeat all steps for the opposite side if replacing both upper control arm bushings
2. Verify all fasteners are properly torqued per specifications
3. Ensure all cotter pins are properly installed and bent to secure

Verification

• Test drive vehicle at low speed and verify no unusual noises from front suspension
• Check for proper steering response and alignment feel
• Have front end alignment checked and adjusted by a qualified technician - bushing replacement will affect camber and caster settings
• After 50-100 miles of driving, re-check control arm bolt torque with vehicle at ride height

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