This procedure covers removal and installation of the front lower control arm on a 2015 Kia Forte 1.8L, including ball joint separation and proper torque sequencing.

Warnings

Tools required

Parts

• Front lower control arm assembly × 1 — Use OEM specification
• Ball joint castle nut × 1 — Replace if cotter pin hole is damaged
• Cotter pin × 1 — New split pin for ball joint

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 frame points
5. Remove front wheel on side being serviced
6. Spray control arm bolts and ball joint nut with penetrating lubricant if vehicle has significant corrosion

Procedure

1. 1

   Remove ball joint cotter pin
   Locate the ball joint castle nut where the lower control arm connects to the steering knuckle. Remove and discard the cotter pin. Straighten the pin with pliers if necessary before extraction.
2. 2

   Loosen ball joint nut
   Using a 19mm socket, loosen the ball joint castle nut but do not remove completely. Leave the nut threaded on 2-3 turns to protect the threads and prevent sudden separation when using the separator tool.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
3. 3

   Separate ball joint from knuckle
   Position the ball joint separator tool between the lower control arm and steering knuckle. Strike the tool or tighten the screw-type separator until the ball joint pops free from the knuckle taper. Remove the castle nut completely once separated.
   ⚠Ball joint will separate suddenly. Keep clear of control arm swing path to avoid pinch injuries.
4. 4

   Support lower control arm
   Place a floor jack under the outer edge of the lower control arm to support its weight and relieve tension on the mounting bolts. Raise just enough to take the load.
5. 5

   Remove rear control arm bolt
   Locate the rear control arm mounting bolt at the subframe. This is the larger 17mm bolt closest to the rear of the vehicle. Remove the bolt completely and note the orientation of any washers or spacers.
   Torque spec

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

   Remove front control arm bolt
   Remove the front control arm mounting bolt at the subframe using a 17mm socket. Support the control arm as you remove the last bolt to prevent it from falling.
   Torque spec

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

   Remove control arm
   Lower the jack and guide the control arm down and out from the vehicle. Maneuver the ball joint stud through the steering knuckle opening. Inspect the removed control arm for torn bushings, cracks, or deformation.
8. 8

   Clean mounting surfaces
   Use a wire brush to clean the subframe mounting bolt holes and surrounding areas. Remove any corrosion, dirt, or old thread locker from the bolt threads and mounting surfaces.
9. 9

   Install new control arm
   Position the new control arm into place, aligning the ball joint stud with the steering knuckle hole. Use the floor jack to support the control arm and align the mounting bolt holes with the subframe.
10. 10

    Install mounting bolts finger-tight
    Insert both front and rear control arm mounting bolts through the subframe and bushings. Thread the bolts in by hand until they are snug but do NOT torque at this time. The suspension must be at ride height before final torque.
    ⚠Do not torque control arm bolts yet. Bolts must be torqued with vehicle weight on wheels to prevent bushing bind.
    Torque spec

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

    Connect ball joint to knuckle
    Raise the control arm with the floor jack to insert the ball joint stud fully into the steering knuckle taper. Install the new castle nut and tighten to specification using a 19mm socket and torque wrench.
    Torque spec

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

    Install cotter pin
    Align the castle nut slots with the ball joint stud hole. If necessary, tighten the nut slightly more (never loosen) to align the slots. Insert a new cotter pin and bend the ends to secure.
13. 13

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand. Lower the vehicle until the tires just contact the ground but the suspension is not fully loaded. Torque the lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)
14. 14

    Final torque control arm bolts at ride height
    With the vehicle on the ground and suspension at normal ride height, torque both control arm mounting bolts (front and rear) to 165 Nm (122 lb-ft). This is critical to prevent bushing failure. A second person may need to bounce the suspension to settle it before final torque.
    ⚠Control arm bolts MUST be torqued at ride height with vehicle weight on wheels. Torquing at full droop will cause premature bushing failure.
    Torque spec

    Control Arm Bolts165 Nm (122 lb-ft)

Reassembly

1. Verify all fasteners are torqued to specification with vehicle at ride height
2. Ensure cotter pin is properly installed and bent to prevent castle nut loosening
3. Remove jack stands and lower vehicle completely to ground

Verification

• Test drive vehicle and verify no clunking or rattling noises from front suspension
• Check for proper steering feel and responsiveness
• Inspect ball joint boot for proper seating with no tears or gaps
• Schedule a professional wheel alignment within 50 miles as suspension geometry has been altered

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