This procedure covers the removal and replacement of the electric power steering rack on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including tie rod disconnection and steering coupler separation.

Warnings

Tools required

Parts

• Electric power steering rack assembly × 1 — Use OEM specification
• Tie rod ends (if reusing rack) × 2 — Use OEM specification
• Cotter pins for tie rod castle nuts × 2 — Use OEM specification
• Steering coupler pinch bolt × 1 — Use OEM specification
• Rack mounting hardware kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and apply parking brake
2. Chock rear wheels securely
3. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
4. Turn steering wheel to center position and verify wheels are straight ahead
5. Install steering wheel lock or insert locking pin through steering column to prevent rotation
6. Raise front of vehicle and support securely on jack stands under frame rails
7. Remove both front wheels
8. Mark tie rod position on threads relative to tie rod end for alignment reference

Procedure

1. 1

   Remove tie rod ends from knuckles
   Remove cotter pins from tie rod end castle nuts and discard. Loosen but do not remove the tie rod end castle nuts. Use a ball joint separator or pickle fork to separate the tie rod ends from the steering knuckles. Once separated, remove the castle nuts completely and set tie rod ends aside.
2. 2

   Disconnect intermediate steering shaft
   Working from inside the cab, locate the intermediate shaft coupler at the base of the steering column where it connects to the rack input shaft. Remove the pinch bolt securing the intermediate shaft to the rack. Mark the orientation of the coupler before separation. Carefully separate the intermediate shaft from the rack input shaft using a pry bar if necessary.
   ⚠Verify steering wheel lock is engaged before disconnecting. Do not allow steering wheel to turn once disconnected.
3. 3

   Remove steering rack mounting bolts
   Locate the steering rack mounting bolts securing the rack to the front crossmember. There are typically four mounting bolts. Support the steering rack with one hand or a transmission jack. Remove all rack mounting bolts and carefully note their positions as they may be different lengths.
4. 4

   Disconnect electrical connector
   Locate the electric power steering motor connector on the rack assembly. Press the release tab and disconnect the electrical connector from the steering rack. Secure the wiring harness out of the way to prevent damage during rack removal.
5. 5

   Remove steering rack from vehicle
   With all connections and mounting bolts removed, carefully maneuver the steering rack assembly out through the driver's side wheel well. The rack may need to be rotated and angled to clear the crossmember and suspension components. Take care not to damage brake lines or other components during removal.
6. 6

   Prepare new steering rack
   Inspect the new or remanufactured steering rack for shipping locks or protective covers and remove them. If transferring tie rods from old rack, measure and mark the thread depth to maintain approximate alignment settings. Clean all mounting surfaces on the crossmember with a wire brush and inspect mounting holes for damage or stripped threads.
7. 7

   Install new steering rack
   Carefully maneuver the new steering rack into position through the driver's side wheel well. Align the rack mounting holes with the crossmember. Insert all mounting bolts finger-tight before final torquing. Verify the rack is properly seated against the crossmember with no gaps or interference.
8. 8

   Torque rack mounting bolts
   Using a calibrated torque wrench, tighten the steering rack mounting bolts to specification. Follow any specified tightening sequence from the service manual if applicable. Verify all bolts are properly seated and torqued.
   ℹ️Verify bolt tightening sequence with factory service manual as improper sequence may cause rack misalignment.
   Torque spec

   Rack Bolts117 Nm (86 lb-ft)
9. 9

   Reconnect electrical connector
   Connect the electrical connector to the power steering motor on the rack assembly. Ensure the connector locks fully into place with an audible click. Verify the connector is secure and the seal is properly seated.
10. 10

    Reconnect intermediate steering shaft
    Align the intermediate steering shaft with the rack input shaft using the alignment marks made during disassembly. Ensure the coupler is fully seated onto the rack shaft. Install a new pinch bolt and tighten to specification. Verify the steering wheel remains centered and locked.
11. 11

    Install tie rod ends
    Thread the tie rod ends into the steering knuckles on both sides. Using the alignment marks made during disassembly as a reference, adjust tie rods to approximate the original position. Install the castle nuts and tighten to specification. Ensure the castle nut slots align with the stud hole. Install new cotter pins and bend tabs to secure.
    ℹ️If castle nut slots do not align with cotter pin hole, tighten further up to one additional hex flat. Never loosen to align.
    Torque spec

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

    Install wheels and lower vehicle
    Install both front wheels and thread lug nuts by hand. Lower the vehicle until the tires contact the ground but not fully weighted. Torque wheel lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
13. 13

    Remove steering wheel lock and reconnect battery
    Remove the steering wheel lock or locking pin from the steering column. Reconnect the negative battery terminal. Turn the ignition to the ON position without starting the engine and verify the power steering warning light behaves normally (illuminates then extinguishes).

Reassembly

1. Reassembly is covered in the main steps above
2. Ensure all electrical connections are secure and properly seated
3. Verify steering wheel remains centered throughout procedure
4. All fasteners must be torqued to specification using a calibrated torque wrench

Verification

• Start engine and verify no power steering warning lights are illuminated on the instrument cluster
• Turn steering wheel lock-to-lock slowly while stationary and listen for unusual noises or binding
• Test drive vehicle at low speed in a safe area and verify steering response is normal with no pulling or wandering
• Verify steering returns to center properly after turns
• Check for any unusual noises during steering operation
• Have vehicle alignment checked and adjusted by a qualified technician as soon as possible after rack replacement
• Inspect all connections and mounting points for proper installation and torque

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