This procedure covers the replacement of the inner and outer rack and pinion boots on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD, protecting the steering rack from contamination.

Warnings

Tools required

Parts

• Rack and pinion inner boot (left) × 1 — Use OEM specification
• Rack and pinion inner boot (right) × 1 — Use OEM specification
• Boot clamps (large) × 4 — Use OEM specification
• Boot clamps (small) × 4 — Use OEM specification
• O-rings for power steering lines × 4 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Rack and pinion grease × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Center the steering wheel and mark position with tape
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove both front wheels
6. Mark tie rod positions relative to inner tie rods with paint or marker for reference

Procedure

1. 1

   Remove tie rod ends from steering knuckles
   Remove the cotter pin from each tie rod end castle nut and discard. Loosen but do not fully remove the tie rod end castle nuts. Use a tie rod end separator or pickle fork to separate the tie rod ends from the steering knuckles. Remove the castle nuts completely and set tie rod ends aside.
2. 2

   Disconnect power steering lines
   Place a drain pan under the steering rack. Using line wrenches, carefully disconnect the power steering pressure and return lines from the steering rack. Allow fluid to drain into the pan. Cap or plug the lines and rack ports to prevent contamination. Remove and discard the old O-rings from the line fittings.
   ⚠Use line wrenches to avoid rounding off the soft brass fittings. Do not use standard open-end wrenches.
3. 3

   Remove steering rack mounting hardware
   Locate the steering rack mounting bolts that secure the rack to the crossmember. Remove the steering rack bolts on both sides. The rack may need to be supported while removing the final bolts. Carefully lower the rack enough to access the boots while keeping it supported.
   ⚠The steering rack is heavy and awkward. Have an assistant help support the rack or use a transmission jack.
   Torque spec

   Rack Bolts117 Nm (86 lb-ft)
4. 4

   Remove outer boot clamps
   Locate the boot clamps on the outer tie rod end of the boot. Use boot clamp pliers or wire cutters to cut and remove the outer clamps on both sides. Note the orientation and position of the clamps for reinstallation reference.
5. 5

   Loosen and remove tie rods from rack
   Count and record the number of threads visible or turns required to remove each tie rod from the inner tie rod end. Loosen the tie rod jam nut, then unthread the outer tie rod from the inner tie rod. Keep left and right sides separated and clearly marked.
   ℹ️Accurate counting of turns is critical to maintain approximate toe alignment settings.
6. 6

   Remove inner boot clamps and boots
   Cut and remove the inner boot clamps that secure the boots to the steering rack housing. Carefully slide the old boots off the rack, working them over the inner tie rod ends. Inspect the rack for any damage, excessive wear, or fluid leakage. Clean the rack housing and inner tie rod threads thoroughly with shop rags.
7. 7

   Install new boots and inner clamps
   Pack the new boots with the specified rack and pinion grease according to manufacturer instructions. Slide the new boots onto the rack from the inner tie rod end, ensuring they seat properly against the rack housing. Install new inner boot clamps and tighten securely using boot clamp pliers, ensuring the clamps are properly seated in the boot grooves.
   ℹ️Boots must be filled with grease to proper level to ensure adequate lubrication and prevent premature failure.
8. 8

   Reinstall tie rods and outer clamps
   Thread the outer tie rods back onto the inner tie rod ends, counting the same number of turns recorded during removal. Tighten the jam nuts to secure the tie rods. Position the boots over the tie rod connections and install new outer boot clamps, tightening securely.
   Torque spec

   Tie Rod Nut62 Nm (46 lb-ft)
9. 9

   Reinstall steering rack
   Raise the steering rack back into position on the crossmember, aligning the mounting bolt holes. Install the steering rack bolts and tighten to specification in an alternating pattern to ensure even seating.
   Torque spec

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

    Reconnect power steering lines
    Install new O-rings on the power steering line fittings, lubricating lightly with clean power steering fluid. Connect the pressure and return lines to the steering rack ports, threading the fittings by hand first to avoid cross-threading. Tighten the power steering line fittings to specification using line wrenches.
    ⚠Ensure new O-rings are properly seated before tightening fittings to prevent leaks.
    Torque spec

    Power Steering Line Fittings30 Nm (22 lb-ft)
11. 11

    Reconnect tie rod ends to knuckles
    Insert the tie rod end studs into the steering knuckle tapers. Install the castle nuts and tighten to specification. Install new cotter pins through the castle nut slots and tie rod stud holes, bending the pins to secure.
    ℹ️If the castle nut slots do not align with the stud hole at specified torque, tighten further to the next slot alignment. Never loosen to align.
    Torque spec

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

    Reinstall wheels and fill power steering fluid
    Install both front wheels and tighten lug nuts in a star pattern to specification. Lower the vehicle to the ground. Fill the power steering reservoir with Motorcraft MERCON LV to the proper level. Start the engine and turn the steering wheel lock-to-lock several times to purge air from the system. Check fluid level and top off as necessary. Inspect all connections for leaks.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Verify all boot clamps are properly seated and tightened
2. Ensure all power steering line connections are secure and not leaking
3. Confirm tie rod jam nuts are properly tightened
4. Double-check that all fasteners are torqued to specification

Verification

• Start engine and turn steering wheel lock-to-lock several times while checking for leaks at rack connections and boots
• Verify power steering operation is smooth with no unusual noises
• Check power steering fluid level is correct after bleeding procedure
• Inspect all boot clamps to ensure they are secure with no movement
• Road test vehicle to verify proper steering operation and no fluid leaks
• Schedule a professional front end alignment to verify toe settings are within specification

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