This procedure covers the removal and replacement of the outer tie rod end on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including proper torque specifications and alignment considerations.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification or equivalent
• Cotter pin × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts on the affected side before raising vehicle
3. Raise front of vehicle and support with jack stands on frame rails
4. Remove wheel completely
5. Spray tie rod end and lock nut threads with penetrating oil if corrosion is present

Procedure

1. 1

   Mark tie rod position
   Before loosening anything, measure and record the distance from the inner tie rod boot to the outer tie rod end. Use a marking pen to mark the position of the outer tie rod end on the inner tie rod threads. This helps maintain approximate alignment for driving to the alignment shop.
2. 2

   Remove cotter pin
   Locate the cotter pin at the tie rod end castle nut where it connects to the steering knuckle. Straighten the cotter pin ends using pliers and pull it completely out. Discard the old cotter pin.
3. 3

   Remove tie rod end castle nut
   Using a 21mm socket, remove the castle nut from the tie rod end stud. Do not remove the tie rod lock nut on the inner tie rod yet. Keep the castle nut if reusing the same tie rod end for measurement purposes.
4. 4

   Separate tie rod end from knuckle
   Use a ball joint separator or pickle fork to separate the tie rod end taper from the steering knuckle. Insert the separator between the knuckle and tie rod end and strike with a hammer until the taper releases. Alternatively, use a tie rod puller tool. Avoid striking the tie rod end threads directly.
   ⚠Using a pickle fork will damage the tie rod end boot. Only use this tool if replacing the tie rod end.
5. 5

   Loosen tie rod lock nut
   Locate the lock nut on the inner tie rod shaft where the outer tie rod end threads on. Use a 19mm wrench to loosen this lock nut but do not remove it completely. It will serve as a reference point.
6. 6

   Count and remove outer tie rod end
   Count the number of exposed threads on the inner tie rod before removal. Unthread the outer tie rod end completely from the inner tie rod shaft by turning it counterclockwise. Keep track of the number of complete turns for reference.
7. 7

   Clean threads and inspect
   Use a wire brush to clean the threads on the inner tie rod shaft. Inspect threads for damage or excessive wear. Check the inner tie rod boot for tears or damage. Replace if necessary.
8. 8

   Install new outer tie rod end
   Thread the new outer tie rod end onto the inner tie rod shaft clockwise. Thread it to the same number of turns or until it aligns with your reference marks. The lock nut should be positioned against the outer tie rod end shoulder.
9. 9

   Install tie rod end into knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the stud is fully seated in the taper. Install the castle nut and tighten to specification. The castle nut slots must align with the cotter pin hole.
   ⚠If castle nut slots do not align with cotter pin hole at specified torque, tighten further to next alignment point. Never loosen the nut to align the cotter pin hole.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut and tie rod stud. Bend the ends of the cotter pin over in opposite directions to secure. Ensure the cotter pin is fully seated and cannot back out.
11. 11

    Snug tie rod lock nut
    Hand-tighten the tie rod lock nut against the outer tie rod end but DO NOT torque to specification yet. The lock nut will be torqued to 78 Nm (58 lb-ft) AFTER the professional wheel alignment is completed.
    ℹ️Final torquing of the lock nut occurs after alignment to prevent changing toe settings.
12. 12

    Reinstall wheel
    Mount the wheel back onto the hub and hand-tighten all lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque all lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Lower vehicle completely and remove jack stands
2. Perform final lug nut torque verification with vehicle on ground
3. Test steering for full range of motion and unusual noises before driving

Verification

• Verify tie rod end castle nut cotter pin is properly installed and secured
• Confirm no looseness in the tie rod end by attempting to move it by hand while knuckle is stationary
• Check that steering wheel turns smoothly lock-to-lock with no binding
• Schedule professional wheel alignment immediately - vehicle will likely pull to one side until aligned
• After alignment is complete, have technician torque the tie rod lock nut to 78 Nm (58 lb-ft)

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