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Repairing Ford® Rear Lower Control Arm Noises
Rich Diegle, Automotive Editor

Some 2005 Ford® Five Hundred®, Freestyle® and Mercury® Montego® FWD vehicles built between 7/12/2004 through 9/21/2004 may exhibit a squeak/clunk from the rear lower control arm bushing at the sub-frame attachment point.

To verify the problem, inspect the rear lower control arm bushing for movement between the bushing and the sub-frame bracket. If the bushing appears to be out of position, or movement is observed, replace the bushing with a revised part (Ford P/N 5F92-438-A). If the bushing shows no signs of movement, diagnose further to pinpoint the source of the noise. For bushing replacement refer to the following Service Procedure.

Ford Control ArmApplicable Vehicles
2005 Ford Five Hundred, Freestyle
2005 Mercury Montego

Service Procedure
Review safety procedures in before beginning

1. On the side(s) of the vehicle where the bushing will be replaced, measure and write down the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height) (Figure 1).

2. Raise vehicle on a hoist so the rear shock is fully extended.

3. Remove the tire/wheel assembly from the affected side of the vehicle.

4. Place a jack stand under the lower control arm near the attachment to outer knuckle.

5. Remove and discard the four (4) stabilizer bar attaching bolts and lower the stabilizer bar to gain access to lower control arm attaching bolt.

Ford Control Arm6. Remove and discard the lower control arm bolt. Some prying/manipulation of the control arm may be required to remove the bolt.

7. Remove lower control arm bushing.

8. Insert the new knurled lower control arm bushing with the lip of the bushing facing the lower control arm nut.

9. Insert the spacer block from an approved Lower Arm Bushing Installer Tool (Figure 2).

10. Position the Arm Bushing Installer Tool over the new bushing with the small cup over the lip of the bushing

11. Tighten the lead screw of the installer tool until the lower control arm bushing is pressed into position and tool cups bottom-out against the frame.

Ford Control Arm12. Remove the installer tool, position the lower control arm over the bushing and install a new lower control arm bolt (Ford P/N W70805-S439). Some prying/twisting of the lower control arm will be required to install the bolt.

13. Before tightening the lower arm bolt, use a jack stand to raise the rear suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). Torque bolt to 92 lb-ft (125 N.m).

14. Reinstall stabilizer bar and new bolts (Ford P/N W709583-S439). Torque to 43 lb-ft (58 N.m).

15. Reinstall tire/wheel and tighten the wheel nuts to 95 lb-ft (129 N.m) in a star-pattern sequence.

Written by ALLDATA Senior Automotive Editor, Rich Diegle. Rich is an Advanced Engine Performance Certified, ASE Master Technician with an AA Degree in automotive technology and 23 years of dealership and independent shop experience. ©2009 ALLDATA LLC. All rights reserved. All technical information, images and specifications are from ALLDATA Repair. ALLDATA is a registered trademark and ALLDATA Repair is a mark of ALLDATA LLC. All other marks are the property of their respective holders. Ford, Mercury, Five Hundred, Freestyle and Montego are registered trademark names and model designations of Ford Motor Company. All trademark names and model designations are being used solely for reference and application purposes.

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