Zone Offroad Products F2302 User manual

»Zone Oroad Products • 491 W. Gareld Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoroad.com
Read and understand all instructions and warnings prior to installation of product
and operation of vehicle.
Zone Oroad Products recommends this system be installed by a professional technician. In addition to these instructions, profes-
sional knowledge of disassembly/ reassembly procedures and post installation checks must be known. Minimum tool requirements
include the following: Assorted metric and standard wrenches, hammer, hydraulic oor jack and a set of jack stands. See the "Special
Tools Required" section for additional tools needed to complete this installation properly and safely.
»Product Safety Warning
Certain Zone Suspension Products are intended to improve o-road performance. Modifying your vehicle for o-road use may result
in the vehicle handling dierently than a factory equipped vehicle. Extreme care must be used to prevent loss of control or vehicle
rollover. Failure to drive your modied vehicle safely may result in serious injury or death. Zone Oroad Products does not recom-
mend the combined use of suspension lifts, body lifts, or other lifting devices.
You should never operate your modied vehicle under the inuence of alcohol or drugs. Always drive your modied vehicle at re-
duced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.
»technical SuPPort
www.zoneoroad.com may have additional information about this product including the
latest instructions, videos, photos, etc.
Send an e-mail to [email protected] detailing your issue for a quick response.
888.998.ZONE Call to speak directly with Zone tech support.
»Pre-inStallation noteS
1. Special literature required: OE Service Manual for model/year of vehicle. Refer to
manual for proper disassembly/reassembly procedures of OE and related compo-
nents.
2. Adhere to recommendations when replacement fasteners, retainers and keep-
ers are called out in the OE manual.
3. Larger rim and tire combinations may increase leverage on suspension, steering,
and related components. When selecting combinations larger than OE, consider
the additional stress you could be inducing on the OE and related components.
4. Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may require
replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced.
5. Secure and properly block vehicle prior to installation of Zone Oroad Products. Always wear safety glasses when using power
tools.
6. If installation is to be performed without a hoist, Zone Oroad Products recommends rear alterations rst.
7. Due to payload options and initial ride height variances, the amount of lift is a base gure. Final ride height dimensions may vary
in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.
rev032020
F2302 Installation Instructions
2021 Ford Bronco
Adventure Series Upper Control Arm
Difficulty Level
easy 1 2 3 4 5 dicult
Estimated installation: 2-3 hours
Special Tools Required
OTC 204-592 Ball Joint Separator
ATD 8696 Ball Joint Press
Tire/Wheel Fitment
Stock wheels and stock tires can be
installed. Taller tires on stock wheels
may contact the UCA. 4.5" to 5" back
spacing wheels is recommended for
most clearance to the UCA. 5.5" back
spacing on a 35" tire will be close to the
UCA at full steering lock.

F2302 Installation - pg. 2
PRE-INSTALLATION NOTES
1. Replacement ball joints can be purchased from a local Ford dealer. Part #
MB3Z-3050-A. Although this control arm reuses the factory ball joint, the ball
joint position is indexed and relocated to correct for alignment and range of mo-
tion for 1"-4" of lift. When used with 1" of lift, caster will be at the high end of
the specication.
2. Will work with Sasquatch, Badlands, or Base model Broncos.
3. Does not t Bronco Sport models.
4. Do NOT hit the aluminum knuckle with a hammer to separate the ball joint. Use
appropriate ball joint separation tool (OTC 204-592).
5. A ball joint press is needed to press out the ball joint in the factory arm and press
it into the Zone Oroad UCA. ATD 8696 ball joint press is recommended and
can be rented from most auto parts stores.
6. Will not work with models with a height sensor attached to the UCA.
7. Fox Coilovers (883-06-195 & 883-06-192) will work with these UCAs
8. Stock height Bilstein Sasquatch or Badlands and black body struts without a
spacer will work with these Zone UCAs.
9. Zone UCAs will work with certain spacer leveling kits, such as ZONF1102,
ZONF1220, ZONF1301, ZONF1302, ZONF1430, and ZONF1431.
INSTALLATION INSTRUCTIONS
1. Park the vehicle on a clean, at surface and block the rear wheels for safety.
2. Raise the front of the vehicle and support with jack stands at the frame rails.
3. Remove the front wheels.
4. Complete this portion of the installation on one side at a time
5. Starting on the passenger side, remove the upper arm shield bolt. Remove the
shield from vehicle and save for later installation Figure 1.
F2302 Kit Contents
Qty Part
1 DRV Arm Assembly
2 Rubber Bushing
1 Zone UCA Badge
1 PASS Arm Assembly
2 Rubber Bushing
1 Zone UCA Badge
2 Ball Joint Caps
2 O-Rings
1 Grease Packet
1 Ball Joint Press Tool - Washer
1 Ball Joint Press Tool - Tube

F2302 Installation - pg. 3
Figure 1
6. Support the knuckle assembly so that the CV shaft and ABS / brake lines are not
overextended when removing the UCA.
7. Remove the upper ball joint nut.
Figure 2
8. Using an appropriate separator, dislodge the upper ball joint from the steering
knuckle Figure 3.
Figure 3
Step 7 Note:
Use the hex holding feature to
prevent the stud from turning while
removing the nut.
Step 8 Note:
Special service tool OTC 204-592
is recommended to dislodge the
ball joint taper.

F2302 Installation - pg. 4
9. Remove the long upper control arm bolt attaching the upper control arm to the
vehicle Figure 4.
Figure 4A
Figure 4A
10. Using a ball joint press and the provided tube and washer press tools the ball
joint will need to be pressed out of the factory arm and into the Zone Oroad
arm.
Figure 5A
Step 9 Note:
When removing the upper control
arm bolt on the driver side the
steering linkage most likely will
need to be disconnected. Make sure
when removing the bolt the steer-
ing wheel does not rotate and the
joint is connected together at the
same position. Damage to the clock
spring may result.
Step 10 Note:
If you choose not to press out the
ball joint in the OE control arm,
they can be purchased from Ford.
OE part # MB3Z-3050-A

F2302 Installation - pg. 5
Figure 5B
11. Remove the snap ring from the top of the ball joint Figure 6. Save for later instal-
lation.
Figure 6
12. Using a at head screw driver, carefully remove the OE ball joint boot Figure 7.
BE VERY CAREFUL NOT TO PUNCTURE THE BOOT.
Figure 7A
Step 11 Note:
Be sure to only press on the ball
joint housing, do NOT press on the
ball stud.

F2302 Installation - pg. 6
Figure 7B
13. Using the provided washer and tube with the ball joint press, Press out the fac-
tory ball joint from the factory control arm Figure 8.
Figure 8A
Provided TubeProvided Tube
Provided WasherProvided Washer
Figure 8B
Step 13 Note:
The press tube has a notch cut into
it to better t the prole of the fac-
tory control arm.
Be sure to use the provided washer
in order to not damage the cap of
the ball joint.
Be sure NOT to press on the ball
stud, but only press on the ball
joint housing.

F2302 Installation - pg. 7
Figure 8C
Figure 8D
14. Install the ball joint into the Zone Oroad upper control arm using the ball joint
press Figure 9.
Figure 9A
Step 14 Note:
The at side on the ball joint hous-
ing must line up with the at side
on the Zone Oroad control arm.
This will ensure the ball joint is
installed in the proper orientation
for range of motion of the joint.
Be sure NOT to press on the ball
stud, but only press on the ball
joint housing.

F2302 Installation - pg. 8
Figure 9B
AA
BB
Figure 9C
AA
BB
Meduim TubeMeduim Tube
Figure 9D
Step 14 Note:
Use the medium sized tube provid-
ed with the ball joint press to press
the ball joint into the Zone Oroad
upper control arm.

F2302 Installation - pg. 9
Figure 9E
15. Install the snap ring on the inside of the ball joint using snap ring pliers Figure
10.
Figure 10
16. Ensure there is no dirt / debris in the ball joint socket. Grease the ball joint and
ball joint boot
Figure 11
17. Install the factory ball joint boot back onto the ball joint using the boot installa-
tion tool in the ball joint press tool set Figure 12A & B.
Step 16 Note:
Grease the OE ball joint boot and
the ball joint before assembly.

F2302 Installation - pg. 10
Figure 12A
Figure 12B
Figure 12C
18. Install new Zone Oroad upper control arm. Replace with factory hardware. Do
not tighten the bushing hardware at this time Figure 13.