This procedure covers the removal and replacement of the power steering gear box (rack and pinion assembly) on a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine and 4WD.

Warnings

Tools required

Parts

• Power steering gear box (rack and pinion) × 1 — Use OEM specification
• Power steering line O-rings × 1 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Rack mounting bushings (if worn) × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV — 1.5 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn steering wheel to center position and lock using steering wheel holder to prevent clockspring damage
3. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove both front wheels
6. Place drain pan under power steering gear box area
7. If equipped with skid plates, remove front skid plate to access steering components

Procedure

1. 1

   Disconnect tie rod ends from steering knuckles
   Remove cotter pins from both tie rod end castle nuts. Loosen but do not remove the tie rod end castle nuts. Use a pickle fork or tie rod separator to separate the tie rod ends from the steering knuckles. Remove the castle nuts completely and set tie rod ends aside.
2. 2

   Remove intermediate steering shaft coupling
   From inside the cab, locate the intermediate steering shaft coupling at the base of the steering column where it connects to the steering gear input shaft. Mark the relationship between the shaft and coupling for reassembly alignment. Remove the lower coupling pinch bolt and separate the coupling from the steering gear input shaft. Do not allow the steering wheel to rotate from center position.
   ⚠Verify steering wheel remains locked and centered. Movement can damage the clockspring assembly.
3. 3

   Disconnect power steering lines
   Using a line wrench to prevent rounding, disconnect the power steering pressure line from the steering gear by loosening the fitting at the gear. Disconnect the return line from the gear. Allow fluid to drain into the drain pan. Cap or plug the lines and gear ports to prevent contamination.
   ⚠Power steering fluid will drain from lines and gear. Ensure drain pan is positioned to catch all fluid.
4. 4

   Remove steering gear mounting bolts
   Locate the steering gear mounting bolts that secure the rack to the front crossmember. There are typically two bolts that pass through mounting brackets. Support the steering gear with one hand or a transmission jack. Remove both mounting bolts while supporting the gear weight.
   ⚠The steering gear assembly is heavy (approximately 30-40 lbs). Ensure adequate support before removing final mounting bolt.
5. 5

   Remove steering gear assembly
   Carefully lower the steering gear assembly and maneuver it out from the driver side of the vehicle. It may be necessary to angle the gear and work it past the front crossmember and suspension components. Take note of any shims or spacers at the mounting points for proper reinstallation.
6. 6

   Prepare new steering gear for installation
   Remove shipping plugs or caps from the new steering gear. Install new O-rings on all power steering line fittings, lubricating them lightly with clean power steering fluid. If reusing tie rod ends, transfer them to the new gear, counting the exact number of turns for each side to maintain approximate alignment settings. Mark the centered position on the new gear's input shaft.
   ℹ️Tie rod thread count is only an approximation. Professional alignment is required after installation.
7. 7

   Install steering gear assembly
   Maneuver the new steering gear into position from the driver side, routing it past suspension components and crossmember. Align the gear to the mounting points on the crossmember. Install any shims or spacers that were removed. Hand-start both mounting bolts before tightening.
8. 8

   Torque steering gear mounting bolts
   Torque the steering gear mounting bolts to specification. If the bolts secure through a bracket, verify the bracket is properly seated before final torquing. Follow the specific torque sequence if provided in the service manual.
   ⚠Improper torque or sequence can cause steering gear misalignment and binding.
   Torque spec

   Rack Bolts117 Nm (86 lb-ft)
9. 9

   Connect power steering lines
   Remove protective caps from steering gear ports and lines. Install the pressure line to the steering gear using a new O-ring, hand-tightening the fitting first. Install the return line to the gear. Torque the pressure line fitting to specification, then torque other line fittings as applicable.
   Torque spec

   Pressure Line Fitting39 Nm (29 lb-ft)

   Power Steering Line Fittings30 Nm (22 lb-ft)
10. 10

    Reconnect intermediate steering shaft
    Align the intermediate steering shaft coupling with the steering gear input shaft, ensuring the previously made alignment marks line up and the gear is in the centered position. Install the pinch bolt and torque according to manufacturer specifications (typically 35-45 Nm, though not provided in torque list - verify with service manual).
    ⚠Misalignment of the steering shaft can cause binding and uneven steering effort.
11. 11

    Reconnect tie rod ends
    Clean the tie rod end tapers and steering knuckle bores. Insert tie rod ends into the steering knuckles. Install the castle nuts and torque to specification. Install new cotter pins through the castle nut slots and tie rod end. Bend cotter pin ends to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
12. 12

    Reinstall wheels and lower vehicle
    Reinstall both front wheels, hand-tightening all lug nuts in a star pattern. Reinstall front skid plate if equipped. Lower the vehicle until the tires just contact the ground but the suspension is not yet fully loaded. Torque all lug nuts to specification in a star pattern. Completely lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
13. 13

    Fill and bleed power steering system
    Remove steering wheel lock. Reconnect negative battery terminal. Fill the power steering reservoir with Motorcraft MERCON LV fluid to the cold fill line. With the engine off, turn the steering wheel lock-to-lock several times slowly. Check fluid level and add as needed. Start the engine and allow to idle. Turn the steering wheel lock-to-lock slowly 5-10 times while checking for leaks at all connections. Check fluid level with engine running and add fluid to bring to hot fill line. Check for any signs of aeration or foaming.
    ⚠Air trapped in the system can cause noise and poor steering performance. Ensure proper bleeding procedure is followed.

Reassembly

1. Verify all power steering line connections are tight and not leaking
2. Confirm steering wheel returns to center properly and steering effort is normal
3. Double-check that all fasteners have been reinstalled and torqued to specification
4. Verify tie rod end cotter pins are properly installed and secured

Verification

• Start engine and verify no power steering fluid leaks at gear or line connections
• Turn steering wheel lock-to-lock and verify smooth operation with no binding or unusual noises
• Test drive vehicle in a safe area at low speed to verify proper steering function and response
• Check power steering fluid level after test drive and top off if necessary
• Schedule front end alignment as soon as possible to ensure proper tire wear and handling

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