This procedure covers the removal and replacement of the front upper control arm on a 2015 Kia Forte with 1.8L I4 engine, including ball joint separation and proper torque specifications.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification
• Ball joint castle nut (if not reusable) × 1 — 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 (do not remove)
4. Raise front of vehicle with floor jack at designated lift point
5. Support vehicle securely on jack stands at manufacturer-specified points
6. Remove front wheel completely

Procedure

1. 1

   Access upper control arm mounting area
   Open hood and locate the upper control arm mounting point at the top of the strut tower. Clear any components or covers that may obstruct access to the mounting bolts. The upper control arm is mounted between the strut tower and the steering knuckle.
2. 2

   Remove upper control arm mounting bolts
   Using appropriate socket, remove the mounting bolts securing the upper control arm to the strut tower/chassis. These are typically two bolts accessed from the engine bay. Support the control arm with your hand as you remove the final bolt to prevent it from dropping.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
3. 3

   Spray ball joint stud and nut
   Apply penetrating oil to the ball joint stud and castle nut where the upper control arm connects to the steering knuckle. Allow 5-10 minutes for penetration if corrosion is present. This is located at the top of the knuckle assembly.
4. 4

   Remove ball joint castle nut
   Remove the cotter pin from the ball joint castle nut if equipped. Using appropriate socket, loosen and remove the castle nut securing the upper control arm ball joint to the steering knuckle. Do not allow the ball joint stud to spin; if necessary, apply pressure to prevent rotation.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
5. 5

   Separate ball joint from knuckle
   Using a ball joint separator or pickle fork, carefully separate the upper control arm ball joint from the steering knuckle. Insert the separator between the control arm and knuckle, then apply pressure to force separation. A sudden release will occur when the taper breaks free.
   ⚠Keep hands and face clear when using separator tool as sudden release can occur.
6. 6

   Remove upper control arm
   Once the ball joint is separated from the knuckle, maneuver the upper control arm out of the vehicle through the wheel well or from above through the engine bay, whichever provides easier access. Inspect the mounting points for damage or excessive corrosion.
7. 7

   Prepare new upper control arm
   Inspect the new upper control arm for any shipping damage. Verify that the ball joint boot is intact and properly seated. Clean the ball joint stud taper and knuckle taper surface with wire brush to ensure proper seating. Apply light coat of anti-seize to mounting bolt threads only (not ball joint taper).
8. 8

   Install new upper control arm to chassis
   Position the new upper control arm into the mounting location at the strut tower. Insert mounting bolts and hand-tighten only at this stage. Do not torque yet as these will need to be final-torqued with vehicle weight on wheels.
9. 9

   Connect ball joint to knuckle
   Align the ball joint stud with the hole in the top of the steering knuckle. You may need to use a pry bar or jack under the lower control arm to position the knuckle correctly. Insert the ball joint stud fully into the knuckle taper until it seats completely.
10. 10

    Install and torque ball joint nut
    Install the new castle nut onto the ball joint stud. Torque the nut to specification: 84.0 Nm (62.0 lb-ft). If using a castle nut, align the nearest slot with the cotter pin hole and install new cotter pin. Never back off the nut to align; if needed, tighten slightly more to reach the next slot.
    Torque spec

    Ball Joint Nut84 Nm (62 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the front wheel and hand-tighten lug nuts in a star pattern. Lower vehicle from jack stands until full vehicle weight is on the suspension but wheel is still slightly off ground. Torque wheel lug nuts to 129.0 Nm (95.0 lb-ft) in star pattern. Fully lower vehicle to ground.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)
12. 12

    Torque upper control arm mounting bolts with weight on wheels
    With vehicle on ground and full weight on suspension, open hood and access the upper control arm mounting bolts at the strut tower. Torque these mounting bolts to final specification: 26.0 Nm (19.0 lb-ft). This ensures bushings are in their neutral position under load.
    ⚠Torquing control arm bolts without vehicle weight on suspension will cause premature bushing wear and potential handling problems.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)

Reassembly

1. Ensure all fasteners have been torqued to specification
2. Verify ball joint castle nut has cotter pin properly installed if applicable
3. Double-check wheel lug nuts are properly torqued

Verification

• Bounce front end of vehicle several times to settle suspension and verify no unusual noises
• Check that steering moves freely through full range of motion without binding
• Visually inspect ball joint connection to ensure it is fully seated in knuckle taper
• Test drive vehicle at low speed in safe area and verify no pulling, vibration, or unusual handling
• Schedule a professional wheel alignment as soon as possible, as this job affects suspension geometry

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