Complete removal and replacement of the electric power steering rack assembly, including disconnecting steering linkage, mounting hardware, and electrical connections.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification for EcoBoost 4WD
• Power steering line O-rings × 4 — High-pressure rated
• Tie rod end cotter pins × 2 — Grade 5 or better
• Rack mounting hardware kit × 1 — If not included with rack

Fluids

• Motorcraft MERCON LV — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Disconnect negative battery terminal and wait 5 minutes for airbag system to discharge
3. Turn steering wheel to center position and install steering wheel holder or remove key to lock wheel
4. Raise front of vehicle and support securely on jack stands behind front crossmember
5. Remove both front wheels
6. Place drain pan under steering rack area
7. Remove engine under-shield and front skid plate if equipped

Procedure

1. 1

   Remove tie rod ends from knuckles
   Remove cotter pins from both tie rod end castle nuts using needle nose pliers. Loosen but do not remove the tie rod end nuts. Use tie rod end puller or ball joint separator to break the taper between tie rod and steering knuckle. Once taper is broken, remove nuts completely and separate tie rod ends from knuckles.
2. 2

   Disconnect steering shaft from rack
   Access the steering shaft coupler at the firewall/rack connection point (may require removal of heat shield). Use a paint pen or scribe to mark the relationship between the intermediate shaft and rack input shaft for reassembly alignment. Remove the steering shaft coupler pinch bolt and carefully separate the intermediate shaft from the rack input shaft. Support the intermediate shaft to prevent damage to clockspring.
   ⚠Do not rotate the steering wheel or intermediate shaft once disconnected, as this can damage the clockspring in the steering column.
3. 3

   Disconnect power steering lines
   Locate the power steering pressure and return lines at the rack. Place drain pan underneath connections. Using appropriate flare nut wrenches, carefully disconnect both power steering line fittings from the rack. Allow fluid to drain completely. Cap or plug open lines and rack ports to prevent contamination. Inspect old O-rings and discard.
   ⚠Power steering fluid will drain from lines and rack. Ensure drain pan is positioned to catch all fluid.
4. 4

   Disconnect electrical connector
   Locate the electrical connector for the electric power steering rack motor (typically on driver side of rack). Press the locking tab and carefully disconnect the electrical connector. Secure the connector away from the work area to prevent damage.
5. 5

   Remove rack mounting bolts
   Locate the steering rack mounting bolts that secure the rack to the front crossmember. There are typically two main mounting bolts. Support the rack with one hand or have an assistant help, as the rack is heavy. Remove both rack mounting bolts completely. On 4WD models, verify clearance around front differential and take note of any additional brackets or hardware.
   ⚠The steering rack assembly weighs approximately 35-45 lbs. Use proper lifting technique and have assistance if needed.
6. 6

   Remove steering rack assembly
   Carefully maneuver the steering rack assembly out from the vehicle. On 4WD models, you may need to lower it down and toward the driver side to clear the front differential. Extend tie rod ends inward if needed to aid removal. Once clear of all mounting points and obstacles, remove the rack from underneath the vehicle.
7. 7

   Prepare new steering rack
   Remove new steering rack from packaging and compare with old unit to verify correct application. Install new O-rings on all power steering line connection points, lubricating lightly with clean MERCON LV fluid. Verify the rack input shaft is in the center position by rotating it lock-to-lock and counting turns, then returning to center. Transfer any necessary brackets or hardware from old rack if not included with new unit.
8. 8

   Install new steering rack
   Carefully maneuver the new steering rack into position from underneath the vehicle, reversing the removal path. On 4WD models, route around the front differential. Align the rack mounting holes with the crossmember mounting points. Hand-thread both rack mounting bolts to ensure proper thread engagement before tightening.
9. 9

   Torque rack mounting bolts
   Using a torque wrench, tighten the steering rack mounting bolts to specification. Tighten in an alternating pattern if applicable to ensure even clamping force. Verify the rack is seated properly against the crossmember before final torquing.
   Torque spec

   Rack Bolts117 Nm (86 lb-ft)
10. 10

    Connect steering shaft to rack
    Align the marks made during disassembly between the intermediate steering shaft and rack input shaft. Verify both are in their centered positions. Carefully slide the intermediate shaft onto the rack input shaft, ensuring the splines engage fully. Install the pinch bolt and torque to specification per service manual (typically 40-50 Nm, verify with service manual).
    ⚠Misalignment of the steering shaft can cause steering wheel off-center condition and may damage the clockspring.
11. 11

    Connect electrical connector
    Route the electrical connector to the power steering rack motor and firmly press into place until the locking tab clicks. Tug gently to verify secure connection. Ensure wiring is routed away from any heat sources or moving components.
12. 12

    Connect power steering lines
    Remove caps or plugs from rack ports and steering lines. Install new lubricated O-rings on line fittings. Thread power steering pressure and return lines by hand onto the rack fittings to ensure proper thread engagement. Using appropriate wrenches, tighten fittings to specification. Do not overtighten as this can damage sealing surfaces.
    Torque spec

    Power Steering Line Fittings30 Nm (22 lb-ft)

    Pressure Line Fitting39 Nm (29 lb-ft)
13. 13

    Install tie rod ends to knuckles
    Insert tie rod end studs into the steering knuckle tapered holes on both sides. Install castle nuts and tighten to specification. Ensure the cotter pin hole in the stud aligns with a castle nut slot. If not aligned, tighten slightly further (do not loosen). Install new cotter pins and bend tabs to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
14. 14

    Install wheels and lower vehicle
    Reinstall both front wheels, hand-threading lug nuts to ensure proper engagement. Lower vehicle until wheels just contact ground. Torque lug nuts in a star pattern to specification. Reinstall engine under-shield and skid plate if equipped. Lower vehicle completely and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
15. 15

    Fill and bleed power steering system
    Remove power steering reservoir cap. Fill reservoir with Motorcraft MERCON LV fluid to the cold fill line. Reconnect negative battery terminal. Remove steering wheel lock. With engine off, turn steering wheel lock-to-lock several times slowly to purge air from system. Check fluid level and add as needed. Start engine and turn wheel lock-to-lock again while monitoring fluid level and listening for noise. Top off fluid to proper level. Check all connections for leaks.
    ℹ️Some air may remain in the system initially. Recheck fluid level after test drive and top off if needed.

Reassembly

1. Verify all fasteners are torqued to specification
2. Verify steering wheel is centered and matches wheel alignment
3. Double-check all electrical connections are secure
4. Ensure no tools or parts were left in the engine bay or underneath vehicle

Verification

• Start engine and verify no warning lights for power steering system
• Turn steering wheel lock-to-lock and listen for unusual noises or binding
• Check all power steering line connections and rack seals for leaks
• Test drive vehicle at low speed in a safe area to verify steering response and center feel
• Recheck power steering fluid level after test drive and top off if needed
• Schedule front-end alignment as soon as possible to ensure proper tire wear and handling

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