Ford F150 Pickup. Instruction — part 1794

2. Install the front suspension lower arm and the torsion bar as an assembly. Install the front stabilizer bar

link to the front suspension lower arm. Install the front shock absorber lower bolt and nut to the front
suspension lower arm. Install lower control arm ball joint through steering knuckle and install a new
cotter pin.

3. Install torsion bar adjuster. Install torsion bar installer/remover and adapter onto torsion bar. Tighten the

installer/remover until the NEW adjustment bolt and nut can be installed. Turn the adjustment bolt until
preliminary adjustment marks are aligned. See Fig. 5 . To complete installation, reverse removal
procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . Check ride
height. See RIDE HEIGHT in ADJUSTMENTS & INSPECTION.

SHOCK ABSORBERS

Removal & Installation

Raise and support vehicle. Remove wheel assembly. Remove upper and lower shock absorber bolts. Compress
shock absorber and remove. To install, reverse removal procedure. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATIONS .

STABILIZER BAR

Removal & Installation

Raise and support vehicle. Remove wheel assembly. Remove skid plate. Remove stabilizer bar link nut at each
end of stabilizer bar. Remove the stabilizer bar link nuts from lower control arms. Remove the links and rubber
bushings. Remove bolts from "U"-shaped support brackets. Rotate and remove stabilizer bar from vehicle. To
install, reverse removal procedure. Tighten all nuts and bolts to specifications. See TORQUE
SPECIFICATIONS .

STEERING KNUCKLE

Removal

1. Raise and support vehicle. Remove wheel assembly. Remove hub and bearing assembly. See HUB &

BEARING ASSEMBLY . Measure length of adjuster bolt extension from adjuster. Mark torsion bar
alignment position. See Fig. 4 .

2. Remove torsion bar adjuster bolt. Install Torsion Bar Installer/Remover (T95T-5310-A) and Adapter

(T96T-5310-A) on torsion bar. See Fig. 5 . Tighten remover/installer until adjuster lifts off adjuster nut.
Remove adjuster bolt and nut. Loosen the torsion bar adjustment tool until the tension is off the torsion
bar.

3. Move Anti-lock Brake System (ABS) sensor and position aside. Remove and discard tie rod end ball joint

cotter pin. Remove tie rod end ball joint castle nut. Using Pitman Arm Puller (T64P-3590-F), separate tie
rod end ball joint from steering knuckle. Remove lower shock absorber bolt. Remove and discard upper

WARNING:

Shock absorbers are gas-filled. DO NOT puncture or apply heat to shock
absorber.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

ball joint cotter pin. Remove upper ball joint castle nut. Using pitman arm puller, separate upper ball joint
from steering knuckle. See Fig. 8 .

4. Remove and discard lower ball joint cotter pin. Remove lower ball joint castle nut. Using pitman arm

puller, separate lower ball joint from steering knuckle. Suspend axle shaft. DO NOT allow axle shaft and
joint to hang unsupported. Remove steering knuckle.

Installation

1. Position the front steering knuckle. Install the front suspension upper control arm ball joint and nut.

Install a new cotter pin. Install the front suspension lower control arm ball joint and nut. Install a new
cotter pin. Install tie-rod end and nut. Install a new cotter pin.

2. Tighten the torsion bar installer/remover until the NEW adjustment bolt and nut can be installed. Turn the

adjustment bolt until preliminary adjustment marks are aligned.

3. To complete installation, reverse removal procedure. Tighten remaining nuts and bolts to specification.

See TORQUE SPECIFICATIONS . Adjust ride height. See RIDE HEIGHT under ADJUSTMENTS
& INSPECTION. Before driving vehicle, pump brake pedal several times to restore normal pedal
position.

TORSION BARS

Removal

1. Raise and support vehicle. Remove wheel and tire assembly. Measure length of adjuster bolt extension

from adjuster. Mark torsion bar alignment position. See Fig. 4 .

2. Remove torsion bar adjuster bolt. Install Torsion Bar Installer/Remover (T95T-5310-A) and Adapter

(T96T-5310-A) on torsion bar. See Fig. 5 . Tighten remover/installer until adjuster lifts off adjuster nut.
Remove adjuster nut. Relieve the torsion bar tension. Remove remover/installer. Remove torsion bar
adjuster. Repeat procedure on other side. Remove torsion bar crossmember support bolts and nuts.
Remove crossmember support. Remove torsion bars.

Installation

CAUTION: The torsion bar adjustment bolt is coated with dry Loctite and must be

replaced if it is backed off or removed. Failure to do so can cause the
adjustment bolt to loosen up during operation and a loss of vehicle
alignment.

CAUTION: The torsion bar adjustment bolt is coated with dry Loctite and must be

replaced if it is backed off or removed. Failure to do so can cause the
adjustment bolt to loosen up during operation and a loss of vehicle
alignment.

NOTE:

Left and right torsion bars are NOT interchangeable. Torsion bars are marked
with an "L" or "R" on one end.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

1. Install torsion bars. Install crossmember support with nuts and bolts. Install torsion bar installer/remover.

Tighten the torsion bar tool until the NEW adjustment bolt and nut can be installed. Turn the adjustment
bolt until preliminary adjustment marks are aligned. Repeat procedure on other side.

2. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE

SPECIFICATIONS . Adjust ride height. See RIDE HEIGHT under ADJUSTMENTS &
INSPECTION.

UPPER CONTROL ARM

Removal

1. Raise and support the vehicle. Remove wheel and tire assembly. Support front suspension under lower

control arm. Mark position of camber adjustment cam. See Fig. 7 . Position the Anti-lock Brake System
(ABS) sensor wire aside.

2. Remove and discard upper ball joint cotter pin. Remove castle nut from upper control arm ball joint stud.

Using Pitman Arm Puller (T64P-3590-F), separate upper control and ball joint from steering knuckle. See
Fig. 8 . Remove upper control arm mounting nuts. Remove upper control pivot bolts. Remove upper
control arm.

Installation

To install, reverse removal procedure. Align camber adjustment marks made during removal. Lubricate ball
joint. With vehicle on floor, tighten upper control arm pivot bolts. See TORQUE SPECIFICATIONS . Check
wheel alignment. See SPECIFICATIONS & PROCEDURES article under WHEEL ALIGNMENT in
SUSPENSION.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup

Fig. 7: Identifying Upper Control Arm Cams
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2002-03 SUSPENSION Front - 4WD Torsion Bar - F150 Pickup