This procedure covers the removal and replacement of the upper control arm on a 2015 Kia Forte with 1.8L engine, including disconnecting the ball joint and control arm mounting bolts.

Warnings

Tools required

Parts

• Upper control arm assembly × 1 — Use OEM specification or quality aftermarket
• Ball joint castle nut (if applicable) × 1 — Reuse if in good condition

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground, but do not remove
3. Raise front of vehicle with floor jack at designated jacking point
4. Support vehicle securely on jack stands placed under frame rails
5. Remove wheel completely
6. Spray penetrating oil on control arm bolts and ball joint nut if corrosion is present

Procedure

1. 1

   Remove wheel and access upper control arm
   With vehicle safely supported, remove the wheel completely to access the upper control arm located at the top of the steering knuckle. Inspect the control arm and ball joint for visible damage or wear.
2. 2

   Remove ball joint castle nut
   Locate the ball joint castle nut where the upper control arm connects to the steering knuckle. Remove cotter pin if equipped. Using a 17mm socket, remove the ball joint nut completely. Keep nut if reusable or have replacement ready.
   ℹ️Some models use a castle nut with cotter pin, others use a self-locking nut. Inspect before removal.
3. 3

   Separate ball joint from knuckle
   Using a ball joint separator tool or pickle fork, carefully separate the upper control arm ball joint from the steering knuckle. Position the separator between the control arm and knuckle, then tighten or strike gently until the taper releases. Support the knuckle to prevent it from dropping.
   ⚠Avoid damaging the ball joint boot or threads. If reusing the ball joint, use a puller-type separator rather than a pickle fork.
4. 4

   Remove control arm mounting bolts
   Locate the two control arm mounting bolts that secure the control arm to the vehicle frame or subframe. Using an 18mm socket and breaker bar, remove both bolts completely. Note the orientation of any washers or spacers for reinstallation.
   ℹ️Control arm may be under slight tension. Support it as you remove the final bolt.
5. 5

   Remove upper control arm
   Once both mounting bolts are removed and ball joint is separated, remove the upper control arm from the vehicle. Inspect the mounting points on the frame for damage, corrosion, or wear. Clean mounting surfaces with wire brush if necessary.
6. 6

   Install new upper control arm
   Position the new upper control arm into place, aligning the mounting holes with the frame. Insert both control arm mounting bolts with any washers or spacers in their original orientation. Thread bolts by hand initially to ensure proper alignment. Do NOT torque at this time.
   ⚠Control arm bolts must remain loose until vehicle weight is on the suspension. Snug them only enough to hold the arm in place.
7. 7

   Connect ball joint to knuckle
   Align the ball joint stud with the hole in the steering knuckle. You may need to use a pry bar or jack under the lower control arm to adjust knuckle position. Insert the ball joint stud fully into the knuckle taper.
8. 8

   Install and torque ball joint nut
   Thread the ball joint castle nut onto the stud by hand, then torque to specification using a torque wrench. If using a castle nut, align the slots with the cotter pin hole and install a new cotter pin. Bend cotter pin ends to secure.
   ⚠Never loosen the nut to align cotter pin holes. Only tighten further if needed for alignment, up to 1/6 turn maximum.
   Torque spec

   Ball Joint Nut84 Nm (62 lb-ft)
9. 9

   Reinstall wheel
   Mount the wheel back onto the hub, threading lug nuts by hand initially. Tighten lug nuts in a star pattern snug but not to final torque yet.
10. 10

    Lower vehicle and torque control arm bolts
    Carefully lower the vehicle from jack stands until the full weight of the vehicle is resting on the wheels and suspension is at normal ride height. With vehicle on the ground, torque both control arm mounting bolts to specification. This ensures proper bushing alignment under load.
    ⚠This is a critical step. Torquing control arm bolts with suspension unloaded will cause premature bushing failure and poor handling.
    Torque spec

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

    Final torque wheel lug nuts
    With vehicle on the ground, torque all wheel lug nuts to specification in a star pattern using a torque wrench.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. Reassembly is covered in the steps above as this procedure involves removal and installation
2. Ensure all fasteners are torqued to specification, particularly the control arm bolts which must be torqued at ride height
3. Double-check that cotter pin is properly installed and secured on ball joint castle nut if applicable

Verification

• Test drive vehicle at low speed and verify no unusual noises from suspension
• Check for proper steering feel and no pulling to one side
• Visually inspect all connections to ensure nothing is loose
• Schedule a front-end alignment within 50 miles, as replacing the upper control arm will affect camber and caster settings
• Re-torque wheel lug nuts after 50-100 miles of driving

More procedures for this vehicle