Power Steering Gear Box

This procedure covers the removal and replacement of the steering gear box (rack and pinion assembly) on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine and RWD configuration.

Warnings

Tools required

Parts

• Steering gear box assembly × 1 — Use OEM specification
• Power steering line O-rings × 4 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn ignition to ON position without starting engine, then turn steering wheel to center position
4. Turn ignition OFF and install steering wheel holding device or insert locking pin to prevent rotation
5. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
6. Raise front of vehicle and support securely on jack stands at frame rails
7. Remove both front wheels
8. Mark the position of tie rod end jam nuts relative to the tie rods for approximate alignment reference
9. Spray all fasteners to be removed with penetrating oil and allow to soak

Procedure

1. 1

   Remove tie rod end cotter pins and castle nuts
   Remove and discard the cotter pins from both outer tie rod end castle nuts. Loosen but do not fully remove the castle nuts at this time. Leave nuts threaded on a few turns to protect the tie rod stud threads during separation.
2. 2

   Separate tie rod ends from steering knuckles
   Using a ball joint separator or pickle fork, separate both outer tie rod ends from the steering knuckles. Once separated, remove the castle nuts completely and set tie rod ends aside. Note the orientation and position for reassembly.
   ⚠Do not damage the tie rod end boots or steering knuckle tapers during separation.
3. 3

   Remove steering shaft coupling pinch bolt
   Locate the intermediate steering shaft coupling at the top of the steering gear box inside the engine bay. Remove the pinch bolt securing the intermediate shaft to the steering gear input shaft. Mark the relationship between the shaft and gear for alignment during reinstallation.
   ⚠Ensure steering wheel remains locked in center position. Movement can damage the clockspring.
4. 4

   Disconnect electrical connector from steering gear
   Locate the electrical connector on the electric power steering gear assembly. Press the release tab and carefully disconnect the wiring harness connector from the steering gear. Secure the harness away from the work area.
5. 5

   Remove steering gear mounting bolts
   Locate the steering gear mounting bolts that secure the assembly to the front crossmember. There are typically two or three main mounting bolts. Support the steering gear with one hand or have an assistant hold it while removing the bolts. Keep track of any washers or spacers.
   ⚠The steering gear assembly is heavy. Ensure proper support to prevent it from falling when the last bolt is removed.
   Torque spec

   Rack Bolts117 Nm (86 lb-ft)
6. 6

   Remove steering gear assembly from vehicle
   Carefully maneuver the steering gear assembly out of the vehicle. It may be necessary to rotate or angle the unit to clear frame rails and other components. Remove through the driver side wheel well area. Place the old unit on a clean work surface.
7. 7

   Transfer tie rod ends to new steering gear (if applicable)
   If your new steering gear does not include tie rod ends, remove them from the old gear and install onto the new unit. Count the number of threads showing on the old gear and match this on the new unit to preserve approximate alignment. Tighten jam nuts securely but do not final torque yet.
   ℹ️Use the marks made during disassembly as a reference for tie rod positioning to minimize alignment deviation.
8. 8

   Inspect and prepare new steering gear
   Inspect the new steering gear for shipping damage. Verify the input shaft rotates smoothly. Check that all protective caps or plugs are removed from ports and mounting surfaces. Apply a thin coat of anti-seize to mounting bolt threads.
9. 9

   Install new steering gear assembly
   Carefully position the new steering gear assembly into the vehicle through the driver side wheel well area. Align the mounting holes with the crossmember. Hand thread all mounting bolts before tightening any. Ensure the gear is properly seated against the crossmember.
10. 10

    Torque steering gear mounting bolts
    Torque the steering gear mounting bolts to specification in an alternating pattern to ensure even clamping force. Verify the gear is fully seated and does not shift during tightening.
    ℹ️Follow the sequence specified in the factory service manual if a specific tightening order is indicated.
    Torque spec

    Rack Bolts117 Nm (86 lb-ft)
11. 11

    Connect intermediate steering shaft
    Align the intermediate steering shaft with the steering gear input shaft using the alignment marks made during disassembly. Ensure the flat or splines are properly engaged. Install the pinch bolt and torque to specification per factory service manual (typically 41-50 Nm or 30-37 lb-ft).
    ⚠Verify proper alignment of steering shaft before tightening pinch bolt. Misalignment can cause binding and premature wear.
12. 12

    Reconnect electrical connector
    Connect the wiring harness connector to the electric power steering gear. Ensure it clicks fully into place and the locking tab is engaged. Verify the connector seal is properly seated.
13. 13

    Install tie rod ends to steering knuckles
    Clean the steering knuckle tapers with a wire brush. Insert the tie rod end studs into the steering knuckle tapers. Install new castle nuts and tighten to specification. Align the castle nut slots with the stud hole and install new cotter pins. Bend cotter pin ends to secure.
    ⚠If the castle nut slots do not align with the stud hole at proper torque, tighten further up to 1/6 turn. Never loosen to align.
    Torque spec

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

    Reinstall wheels and lower vehicle
    Install both front wheels and hand tighten lug nuts in a star pattern. Lower the vehicle until the tires just touch the ground. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

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

    Reconnect battery and perform system initialization
    Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine. Allow the power steering system to complete its self-test (typically 30-60 seconds). Start the engine and verify the power steering warning light is not illuminated.

Reassembly

1. Remove steering wheel holding device or locking pin after intermediate shaft is reconnected
2. Verify all electrical connectors are properly secured and locked
3. Check that no tools or parts were left in the engine bay or wheel well areas
4. Verify all mounting bolts are torqued to specification
5. Ensure tie rod end jam nuts are tightened after alignment is performed

Verification

• Start the engine and verify no power steering warning lights are illuminated on the instrument cluster
• Turn the steering wheel slowly from lock to lock while stationary and verify smooth operation with no binding or unusual noises
• Test drive the vehicle at low speed in a safe area and verify steering response is normal with no pulling or wandering
• Check for any unusual noises during steering input
• Verify steering wheel returns to center properly after turning
• Have a professional wheel alignment performed as soon as possible to ensure proper tire wear and handling
• After alignment, verify tie rod end jam nuts are properly tightened and torque to specification if needed
• Recheck all mounting bolt torque after first 50-100 miles of driving

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