This procedure covers the removal and replacement of the power steering rack assembly on a 2011-2014 Ford F-150 with 5.0L V8 engine and 4WD, including tie rod disconnect, rack mounting, and hydraulic line connections.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification
• Power steering line O-rings × 1 — Typically included with rack
• Tie rod end cotter pins × 2 — 3/32-inch diameter
• Rack mounting bushings × 2 — Inspect and replace if worn

Fluids

• Motorcraft MERCON LV — 1.5 qt

Preparation

1. Park vehicle on level surface and set parking brake. Place wheel chocks behind rear wheels.
2. Center the steering wheel and lock it in position using a steering wheel holder or seat belt through the wheel.
3. Disconnect negative battery terminal and wait 10 minutes for airbag system to discharge.
4. Remove reservoir cap and use turkey baster to extract as much power steering fluid as possible from reservoir.
5. Raise front of vehicle and support securely on jack stands positioned under frame rails.
6. Remove both front wheels.
7. Place catch pans under steering rack area to collect remaining power steering fluid.

Procedure

1. 1

   Remove front skid plate (if equipped)
   Remove the bolts securing the front skid plate or underbody shield. This provides access to the steering rack and related components. Set aside the skid plate and hardware.
2. 2

   Disconnect tie rod ends from steering knuckles
   Remove the cotter pins from both tie rod end castle nuts using needle nose pliers. Loosen but do not remove the castle nuts. Use a tie rod end separator tool to break the taper between the tie rod end and knuckle. Once separated, remove the castle nuts completely and remove tie rod ends from knuckles. Support the tie rods to prevent damage to boots.
   ⚠Do not hammer directly on tie rod ends or threads as this can damage components. Use a proper separator tool.
   Torque spec

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

   Mark and disconnect outer tie rods
   Before removing outer tie rods from inner tie rods, measure and record the exposed thread length or mark the position with paint or tape for reference during reassembly. Loosen the tie rod jam nuts and unthread the outer tie rods from the inner tie rods, counting the number of turns for each side.
   ℹ️Recording the exact position helps minimize alignment changes, though professional alignment will still be required.
4. 4

   Disconnect intermediate steering shaft
   Locate the intermediate shaft coupler connection at the steering rack input shaft. Mark the relationship between the shaft and rack pinion for proper reassembly alignment. Remove the pinch bolt from the coupler and separate the intermediate shaft from the rack input shaft. Support the shaft to prevent it from hanging and stressing the upper connection.
   ⚠Do not allow the intermediate shaft to rotate independently or the clockspring may become misaligned.
5. 5

   Disconnect power steering pressure line
   Using a flare nut wrench to prevent rounding, loosen and remove the pressure line fitting from the steering rack. Allow fluid to drain into catch pan. Remove and discard the O-ring seal. Cap or plug the line and rack port to prevent contamination.
   ⚠Use a flare nut wrench to prevent damage to the soft brass fittings. Standard open-end wrenches may round the fitting.
   Torque spec

   Pressure Line Fitting42 Nm (31 lb-ft)
6. 6

   Disconnect power steering return line
   Loosen and remove the return line fitting from the steering rack using appropriate flare nut wrench. Allow remaining fluid to drain completely into catch pan. Remove and discard the O-ring seal. Cap or plug the line and rack port.
   Torque spec

   Power Steering Line Fittings30 Nm (22 lb-ft)
7. 7

   Remove rack mounting bolts
   Locate the two steering rack mounting bolts that secure the rack to the front crossmember. Support the rack with a transmission jack or have an assistant support it by hand. Remove both rack mounting bolts completely. Note the location and orientation of any brackets or heat shields attached to the mounting points.
   ⚠The rack assembly is heavy and awkward. Use proper support to prevent the rack from falling when bolts are removed.
   Torque spec

   Rack Bolts127 Nm (94 lb-ft)
8. 8

   Remove steering rack assembly
   With mounting bolts removed and all connections disconnected, carefully maneuver the steering rack assembly out through the driver side wheel well area. The rack will need to be tilted and rotated to clear the frame rails and crossmember. Take care not to damage the inner tie rod boots during removal. Lower the rack once clear of the vehicle.
   ℹ️This is the most physically challenging step. A second person can make this significantly easier.
9. 9

   Prepare new rack for installation
   If inner tie rods were not transferred, install them onto the new rack per manufacturer specifications. Extend the rack to the same position as the old rack was centered. Install new O-rings onto the pressure and return line ports, lubricating lightly with clean power steering fluid. Verify all mounting bushings are in place on the new rack.
   ℹ️Compare the old and new rack assemblies to ensure all necessary components are transferred or included.
10. 10

    Install new steering rack
    Carefully maneuver the new rack assembly into position through the driver side wheel well area, reversing the removal process. Align the rack mounting holes with the crossmember mounting points. Install rack mounting bolts hand-tight initially but do not torque yet. Ensure no hoses or wires are pinched.
    ⚠Verify the rack is centered before final installation to ensure equal turning radius in both directions.
11. 11

    Torque rack mounting bolts
    Using a torque wrench, tighten the steering rack mounting bolts to specification. If different torque values are listed for Rack Bolts versus Steering Rack Bolts, verify which applies to your specific mounting configuration in the service manual. Tighten evenly and verify rack is seated properly against mounting surface.
    Torque spec

    Rack Bolts127 Nm (94 lb-ft)
12. 12

    Connect power steering lines
    Install the pressure line to the rack with new O-ring, starting threads by hand to prevent cross-threading. Tighten to specification using a flare nut wrench. Install the return line with new O-ring and tighten to specification. Verify both fittings are properly seated and not cross-threaded.
    ⚠Do not overtighten hydraulic fittings. Use exact torque specifications to prevent leaks or fitting damage.
    Torque spec

    Pressure Line Fitting42 Nm (31 lb-ft)

    Power Steering Line Fittings30 Nm (22 lb-ft)
13. 13

    Reconnect intermediate steering shaft
    Align the marks made during disassembly and slide the intermediate shaft coupler onto the rack input shaft. Verify the steering wheel is still centered and locked. Install the pinch bolt and tighten securely. Verify there is no binding in the steering shaft throughout the range of motion.
    ⚠Incorrect alignment of the intermediate shaft can cause steering wheel off-center condition and premature wear.
14. 14

    Reinstall outer tie rods
    Thread the outer tie rods onto the inner tie rods to the previously marked position or counted number of turns. This will approximate the original alignment settings. Tighten the jam nuts but do not torque yet as final adjustment may be needed after alignment check.
    Torque spec

    Tie Rod Nut68 Nm (50 lb-ft)
15. 15

    Reconnect tie rod ends to knuckles
    Insert the tie rod end studs into the steering knuckles. Install the castle nuts and tighten to specification. Verify the castellations align with the cotter pin hole. If not, tighten slightly more until alignment is achieved (never loosen to align). Install new cotter pins and bend tabs to secure.
    ⚠Always use new cotter pins. Reusing old cotter pins can lead to failure and loss of steering control.
    Torque spec

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

Reassembly

1. Reinstall front skid plate or underbody shield if equipped.
2. Install front wheels and torque lug nuts to specification in a star pattern.
3. Lower vehicle from jack stands.
4. Fill power steering reservoir with Motorcraft MERCON LV fluid to the cold fill line.
5. With engine off, turn steering wheel lock-to-lock several times to purge air from system.
6. Start engine and turn steering wheel lock-to-lock again while monitoring fluid level.
7. Add fluid as necessary and check for leaks at all hydraulic connections.
8. Reconnect negative battery terminal.
9. Remove steering wheel lock.

Verification

• With engine running, verify smooth power steering operation with no unusual noises or binding throughout the full steering range.
• Check for power steering fluid leaks at the rack body, pressure line, return line, and all fittings.
• Verify steering wheel returns to center naturally after turning.
• Road test vehicle at low speed in a safe area to verify proper steering response and no pulling.
• Check power steering fluid level after test drive and top off if necessary.
• Schedule professional four-wheel alignment as soon as possible to verify and correct toe settings and ensure even tire wear.

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