Ford Aerostar 1986-1997 Repair Guide

Upper Control Arm



See Figures 1 and 2

  1. Place the steering wheel and front tires in the centered (straight ahead) position.

Anytime the steering linkage is disconnected from the spindle, the steering system must be centered before beginning the service procedure.

  1. Raise the van and support it safely with jackstands placed under the frame lifting pads. A hydraulic floor jack should be placed under the control arm to raise and lower the arm during coil spring removal. Make sure the van is supported securely on the jackstands and only work on one side at a time.

NEVER service both front suspension assemblies at the same time.

  1. Remove the spindle, as described in this section.
  3. Remove the bolt retaining the cowl drain bracket and bolt retainer plate, then remove the bracket and plate.
  5. Matchmark the position of the control arm mounting brackets on the flat plate.
  7. Remove the bolt and washer retaining the front mounting bracket to the flat plate.
  9. From beneath the rail, remove the three nuts from the bolts retaining the two upper control arm mounting brackets to the body rail.
  11. Remove the three long bolts retaining the mounting brackets to the body rail by rotating the upper control arm out of position in order to remove the bolts. Remove the upper control arm, upper ball joint and mounting bracket assembly, and the flat plate from the van.
  13. If necessary, remove the damper assembly from the upper control arm by removing the three retaining bolts.
  15. Inspect the upper and/or lower ball joint boot seal and replace if necessary.
  17. If required to service the upper control arm and upper ball joint assembly or the mounting brackets and adjusting arm assembly, remove the nuts retaining the upper control arm to the adjusting arm. Note the exact position and number of shims on each control arm stud. These shims control caster and camber. Remove the upper control arm from the adjusting arm.

The adjusting arm and mounting brackets are serviced as an assembly, Ford recommends that the upper control arm and upper ball joint also be serviced as an assembly; however, aftermarket ball joint kits are available.

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the upper control arm and front crossmember-1986-90 models (1991-96 same except for torque specifications)

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