This procedure covers the removal and replacement of the outer tie rod end assembly 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 assembly × 1 — Use OEM specification or quality aftermarket
• Cotter pin × 1 — Check tie rod end diameter for correct size
• Anti-seize compound × 1 — Use high-temperature rated

Preparation

1. Park vehicle on level surface and apply parking brake
2. Loosen wheel lug nuts on the side being serviced while vehicle is on ground
3. Raise and support vehicle securely with jack stands under the frame
4. Remove wheel and tire assembly completely
5. Spray tie rod end threads and castle nut with penetrating oil and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark alignment reference position
   Before removing the tie rod end, use a white paint marker or grease pencil to mark the position of the tie rod end on the threaded sleeve. Count and record the number of visible threads between the tie rod end and the lock nut. This will help maintain approximate alignment during installation.
2. 2

   Remove cotter pin
   Straighten the legs of the cotter pin in the tie rod end castle nut using pliers or a cotter pin removal tool. Pull the cotter pin completely out and discard. If the cotter pin is damaged or difficult to remove, use side cutters to clip it off.
3. 3

   Loosen tie rod end castle nut
   Using a 22mm wrench or socket, loosen but do not completely remove the castle nut on the tie rod end at the steering knuckle. Leave the nut threaded on approximately 2-3 turns to protect the threads during separation.
4. 4

   Separate tie rod end from knuckle
   Insert a tie rod end separator (pickle fork) or ball joint separator between the steering knuckle and tie rod end. Strike the tool firmly with a hammer to break the taper connection. Once separated, remove the castle nut completely and pull the tie rod end stud out of the knuckle. Note: The pickle fork method will damage the tie rod end boot, so only use if replacing the tie rod.
5. 5

   Loosen tie rod lock nut
   Using a 19mm wrench, loosen the lock nut that secures the tie rod end to the inner tie rod sleeve. Do not remove it completely yet - back it off toward the inner tie rod to expose the threads.
6. 6

   Remove outer tie rod end
   While holding the inner tie rod sleeve stationary with a wrench (if necessary), unthread the outer tie rod end by turning it counterclockwise. Count the number of complete turns as you remove it and record this number for installation reference. Remove the lock nut from the threads once the tie rod end is off.
7. 7

   Inspect and clean threads
   Inspect the inner tie rod threads for damage, rust, or debris. Use a wire brush to clean the threads thoroughly. Check the steering boot for tears or damage. Apply a light coat of anti-seize compound to the cleaned threads to prevent future seizing and facilitate accurate torque readings.
8. 8

   Install new tie rod end
   Thread the lock nut onto the inner tie rod threads first, moving it toward the steering rack. Thread the new outer tie rod end onto the inner tie rod clockwise, using the same number of turns recorded during removal. Align with the reference marks made earlier. Do not tighten the lock nut yet.
9. 9

   Install tie rod end to knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the stud seats fully into the taper. Install the castle nut and tighten to specification. The castle nut slots must align with the cotter pin hole in the stud. If necessary, tighten the nut slightly more (never loosen) to achieve alignment with the next castle slot.
   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 hole. Bend the legs of the cotter pin around the castle nut - one leg should wrap around the back of the nut, and the other can be bent upward or to the side. Ensure the cotter pin is secure and cannot back out.
11. 11

    Reinstall wheel assembly
    Position the wheel onto the hub and install all lug nuts by hand. Tighten lug nuts in a star pattern until snug but not fully torqued. Lower vehicle until tire just touches the ground to prevent wheel rotation.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
12. 12

    Final torque wheel lug nuts
    With vehicle weight on the ground, torque the wheel lug nuts to specification in a star/cross pattern. Make at least two complete passes to ensure even seating and accurate torque.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Do NOT tighten the tie rod lock nut until after professional alignment is completed
2. After alignment, torque the tie rod lock nut to 78 Nm (58 lb-ft) while holding the tie rod end stationary
3. Verify cotter pin is properly installed and secured after all work is complete
4. Test drive vehicle at low speed in a safe area to verify steering response before normal operation

Verification

• Verify tie rod end stud is fully seated in steering knuckle taper with no play
• Confirm cotter pin is properly installed and bent to prevent backing out
• Check that all fasteners are torqued to specification
• Verify no interference between tie rod and suspension components through full steering travel
• Schedule professional wheel alignment immediately - vehicle should not be driven extensively until aligned
• After alignment, verify tie rod lock nut is torqued to 78 Nm (58 lb-ft)

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