Here's a general outline of the process. Always consult a repair manual specific to your 2003 Ford Expedition (e.g., a Haynes or Chilton manual) for detailed instructions and torque specifications. These specifications are crucial for safety and proper vehicle handling. Improper torque can lead to premature wear or failure of components.
Tools You'll Likely Need:
* Jack and Jack Stands: Essential for safely lifting the vehicle. Never work under a vehicle supported only by a jack.
* Wheel Chocks: To secure the vehicle.
* Lug Wrench: To remove the wheels.
* Sockets and Wrenches (metric): Various sizes, including those needed for the control arm bolts, ball joint, and other related fasteners. A ratchet set is highly recommended.
* Torque Wrench: Absolutely necessary to tighten bolts to the manufacturer's specifications.
* Ball Joint Separator: To separate the ball joint from the steering knuckle. A pickle fork can be used, but it risks damaging the ball joint. A ball joint press is the best option.
* Hammer and Punch (optional): May be needed to help break loose stubborn bolts.
* Penetrating Oil (PB Blaster or similar): Apply liberally to bolts before attempting to remove them. Let it soak for a while.
* Floor Jack (optional, but helpful): To support the control arm during removal and installation.
* Safety Glasses and Gloves: Protect yourself from injury.
General Steps (Consult your repair manual for specifics):
1. Safety First: Park on a level surface, engage the parking brake, and chock the wheels. Disconnect the negative battery terminal.
2. Suspension Prep: Support the vehicle securely on jack stands. Remove the wheel from the side you're working on.
3. Disconnect Sway Bar Link: Disconnect the sway bar link from the control arm. This will vary slightly depending on your specific vehicle.
4. Disconnect Ball Joint: This is often the most challenging part. Use your ball joint separator to carefully separate the ball joint from the steering knuckle. Be cautious not to damage the boot.
5. Remove Control Arm Bolts: Locate and remove the bolts attaching the upper control arm to the frame and the knuckle. Penetrating oil will be your friend here. These bolts can be very stubborn.
6. Remove Control Arm: Once all bolts are removed, carefully lower the control arm. You may need a floor jack to support the arm during removal.
7. Install New Control Arm: Install the new upper control arm, ensuring it's properly aligned. Install the bolts and tighten them *slightly*.
8. Reconnect Ball Joint: Carefully reconnect the ball joint to the steering knuckle.
9. Reconnect Sway Bar Link: Reconnect the sway bar link.
10. Tighten Bolts: Use your torque wrench to tighten all bolts to the manufacturer's specified torque settings (found in your repair manual). This is crucial for safety and proper alignment.
11. Reinstall Wheel and Lower Vehicle: Carefully lower the vehicle to the ground. Install the wheel and torque the lug nuts to specification.
12. Repeat for Other Side (if necessary): Repeat the process for the other side if both upper control arms need replacing.
13. Wheel Alignment: After replacing the control arms, you absolutely must have a wheel alignment performed by a professional. Incorrect alignment can lead to premature tire wear, poor handling, and even accidents.
Important Considerations:
* Parts: Ensure you purchase the correct upper control arms for your specific 2003 Ford Expedition model. There might be variations based on trim level and options.
* Alignment: As mentioned, a wheel alignment is essential after this repair.
* Safety: This is a complex repair. If you're not comfortable with any step, don't hesitate to consult a professional.
This is a simplified overview. Always consult a repair manual for your specific vehicle for detailed instructions, torque specifications, and diagrams. Working on your vehicle's suspension system is a serious undertaking, so proceed with caution and prioritize safety.
