Power Steering Gear Box

Complete replacement of the power steering gear box (steering rack) on a 2011-2014 Ford F-150 with 5.0L V8 Coyote engine, including removal of skid plates, steering linkage disconnection, and rack installation.

Warnings

Tools required

Parts

• Power steering gear box (rack assembly) × 1 — Use OEM Ford specification for 4WD application
• Power steering line O-rings × 1 — High-pressure and return line O-rings
• Cotter pins for tie rod ends × 2 — 3/16 inch diameter
• Motorcraft MERCON LV power steering fluid × 2 — XT-10-QLVC

Fluids

• Motorcraft MERCON LV — 1.5 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Mark the steering wheel position at 12 o'clock with tape, ensuring wheels are pointed straight ahead
3. Lock the steering wheel using ignition lock or a steering wheel holding tool to prevent rotation
4. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge
5. Loosen front wheel lug nuts while vehicle is on ground
6. Raise front of vehicle and support securely on jack stands at frame rails behind front suspension
7. Remove both front wheels
8. Place drain pan under power steering reservoir and use turkey baster to remove as much fluid as possible from reservoir
9. Remove engine skid plate and front differential skid plate (if equipped)

Procedure

1. 1

   Disconnect steering column from rack
   From inside the cab, locate the steering shaft coupler at the firewall. Remove the lower steering column trim panel if necessary for access. Mark the relationship between the steering shaft and the rack input shaft with paint or a center punch. Remove the steering shaft coupler pinch bolt (typically 18mm). Separate the steering column shaft from the rack input shaft by pulling upward on the steering column shaft.
2. 2

   Disconnect outer tie rod ends
   On both sides, remove the cotter pin from the tie rod end castle nut. Loosen but do not remove the castle nut. Using a ball joint separator or pickle fork, separate the tie rod end from the steering knuckle. Remove the castle nut completely and lift the tie rod end out of the knuckle. Mark the position of the tie rod adjustment sleeve for reference during reassembly.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Disconnect power steering lines
   Position drain pan beneath the rack. Using the appropriate line disconnect tool, release the pressure line fitting from the rack. Allow fluid to drain completely. Disconnect the return line fitting. Cap or plug both lines and both rack ports to prevent contamination. Inspect O-rings on lines and note their condition for replacement.
   ⚠Power steering fluid may be hot if vehicle was recently operated. Fluid will drain rapidly from pressure line.
4. 4

   Remove rack mounting hardware
   Locate the two rack mounting bolts that secure the rack to the front crossmember. These are typically accessed from above and below the crossmember. On 4WD models, there may be additional clearance required around the front differential. Support the rack with one hand or a transmission jack. Remove both rack mounting bolts completely while supporting the rack weight.
   ⚠The rack assembly weighs approximately 25-30 pounds. Ensure adequate support before removing final mounting bolt.
   Torque spec

   Rack Bolts127 Nm (94 lb-ft)
5. 5

   Remove rack assembly from vehicle
   With mounting bolts removed, carefully maneuver the rack assembly toward the driver's side of the vehicle. On 4WD models, rotate the rack to clear the front differential housing. The rack must be angled and rotated to pass through the front suspension and frame rails. Feed the rack out through the driver's side wheel well opening. Keep track of any spacers or bushings from the mounting points.
6. 6

   Prepare new rack for installation
   Verify the new rack is the correct part for 4WD application. Ensure rack is centered: measure tie rod extension on both sides to confirm equal length. Install new O-rings on power steering line fittings, lubricating lightly with power steering fluid. Compare new rack mounting bushings and brackets with old unit and transfer if necessary. Verify rack input shaft splines are clean and undamaged.
7. 7

   Install new rack assembly
   Maneuver the new rack into position by reversing the removal path through the driver's side wheel well. Rotate and angle as needed to clear the front differential on 4WD models. Align the rack mounting holes with the crossmember. Install both mounting bolts finger-tight initially to ensure proper alignment. Verify rack is fully seated against mounting surface before tightening.
8. 8

   Torque rack mounting bolts
   Using a calibrated torque wrench, tighten the rack mounting bolts to specification in an alternating pattern. Start with one bolt, torque to 50% of final spec, then torque the second bolt to 50%, then torque both to final specification. This ensures even seating of the rack against the crossmember.
   Torque spec

   Rack Bolts127 Nm (94 lb-ft)
9. 9

   Reconnect power steering lines
   Remove caps or plugs from rack ports and line fittings. Install the pressure line first, ensuring the new O-ring is properly seated. Thread fitting by hand several turns to prevent cross-threading. Torque pressure line fitting to specification. Install return line with new O-ring and torque to specification. Verify both connections are clean and properly seated.
   ℹ️New O-rings must be used on all power steering line connections to prevent leaks.
   Torque spec

   Pressure Line Fitting42 Nm (31 lb-ft)

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

    Reconnect steering column shaft
    Verify steering wheel is still locked in centered position. From under the dash, align the steering column shaft with the rack input shaft using the alignment marks made during disassembly. Ensure the shaft slides fully onto the splines. Install the pinch bolt and torque to specification per Ford service manual (typically 35-45 Nm, but verify with service manual as this critical fastener is not in the provided torque list).
    ⚠️Misalignment of the steering shaft can cause loss of steering control and clockspring damage. Verify marks align exactly.
11. 11

    Reconnect outer tie rod ends
    Thread the tie rod ends into the steering knuckles on both sides. Install the castle nuts and torque to specification. Install new cotter pins through the castle nut slots and tie rod end studs. If the castle nut slots do not align with the stud hole, tighten the nut slightly (do not back off) until alignment is achieved. Bend cotter pin ends to secure.
    ⚠Never loosen a castle nut to align cotter pin holes. Only tighten further to achieve alignment.
    Torque spec

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

    Reinstall skid plates and wheels
    Reinstall the front differential skid plate and engine skid plate, ensuring all mounting bolts are properly torqued per service manual specifications. Install both front wheels and thread lug nuts by hand. Lower vehicle until tires just touch the ground but weight is still on jack stands.
13. 13

    Fill and bleed power steering system
    Fill power steering reservoir with Motorcraft MERCON LV fluid to the COLD MAX mark. Unlock steering wheel and reconnect battery negative terminal. Without starting engine, turn steering wheel slowly lock-to-lock 10 times. Check fluid level and add as needed. Start engine and turn steering wheel lock-to-lock 5 times while idling. Check for leaks at all connections. Turn off engine, check fluid level and top off to HOT MAX mark.
    ⚠Do not hold steering wheel against the lock stops for more than 5 seconds to prevent pump damage.
14. 14

    Final torque of wheel lug nuts
    With vehicle still slightly supported, torque all wheel lug nuts to 50% of specification in a star pattern. Fully lower vehicle to ground. Torque all wheel lug nuts to full specification in a star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. All torque specifications must be achieved using a calibrated torque wrench
2. New O-rings are mandatory for all power steering line connections
3. New cotter pins are mandatory for tie rod end castle nuts
4. Verify steering wheel remains centered throughout procedure to prevent clockspring damage
5. All skid plate fasteners should be reinstalled with thread locker if originally equipped

Verification

• Start engine and verify no power steering fluid leaks at rack connections or line fittings
• With engine running, turn steering wheel lock-to-lock and verify smooth operation with no binding or unusual noises
• Check power steering fluid level with engine at operating temperature and top off if needed
• Verify steering wheel is centered when wheels are pointed straight ahead
• Test drive vehicle at low speed in a safe area to verify proper steering function and responsiveness
• Re-check all connection points for leaks after test drive
• Schedule front-end alignment as soon as possible, as tie rod positions may have shifted slightly

More procedures for this vehicle