This procedure covers the replacement of the inner and outer rack and pinion boots on a 2015-2020 Ford F-150 3.5L EcoBoost RWD to prevent contamination of the steering rack.

Warnings

Tools required

Parts

• Rack and pinion boot kit (inner and outer boots with clamps) × 1 — Use OEM specification
• Tie rod end cotter pin × 2 — Use OEM specification
• Grease (if not included in boot kit) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-recommended lift points
5. Remove both front wheels completely
6. Clean steering rack area with brake cleaner to prevent contamination during boot replacement

Procedure

1. 1

   Mark tie rod position
   Before removing any components, measure and mark the exposed thread length on the tie rod between the inner and outer tie rod ends. Use a ruler to measure from the inner tie rod jam nut to the end of the outer tie rod threads, or mark both components with paint where they meet. This ensures proper alignment restoration.
2. 2

   Remove outer tie rod end cotter pin and castle nut
   Straighten and remove the cotter pin from the outer tie rod end castle nut at the steering knuckle. Remove the castle nut completely. Discard the old cotter pin.
   Torque spec

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

   Separate outer tie rod end from knuckle
   Use a tie rod separator tool or pickle fork to separate the outer tie rod end taper from the steering knuckle. Strike the tool with a hammer if necessary. Once separated, support the tie rod end to prevent damage to the boot you may be replacing.
4. 4

   Loosen outer tie rod jam nut
   Loosen the jam nut that locks the outer tie rod end to the inner tie rod. Do not remove completely yet. Count and record the number of turns or visible threads for reference during reassembly.
5. 5

   Remove outer tie rod end
   Unthread the outer tie rod end from the inner tie rod by turning counterclockwise. Count the number of rotations required for removal to aid in reinstallation at the same position. Once removed, remove the jam nut from the inner tie rod.
6. 6

   Remove old outer boot and clamps
   Cut or remove the clamps securing the outer boot to the inner tie rod and steering rack bellows area. Slide the old outer boot off the inner tie rod. Inspect the inner tie rod threads and rack housing for damage or excessive wear.
7. 7

   Remove inner tie rod
   Using an inner tie rod tool or large adjustable wrench on the flats of the inner tie rod, unthread it from the steering rack. Turn counterclockwise to remove. Support the rack to prevent rotation during removal. Once removed, inspect the rack threads.
   ⚠Do not use the tie rod threads or ball joint to grip during removal as this will damage components.
   Torque spec

   Tie Rod Nut62 Nm (46 lb-ft)
8. 8

   Remove inner boot and inspect rack
   Remove the clamps securing the inner boot to the steering rack housing. Slide the inner boot off the rack. Thoroughly inspect the rack shaft for scoring, corrosion, or grease contamination. Wipe clean with a rag and brake cleaner. If rack shows damage, boot replacement alone may not solve steering issues.
9. 9

   Install new inner boot
   Slide the new inner boot onto the steering rack shaft, ensuring it seats properly in the groove on the rack housing. Install the inner clamp first, positioning it in the boot groove nearest the rack housing. Tighten the clamp securely using boot clamp pliers or carefully with a screwdriver to avoid damaging the boot.
10. 10

    Apply grease and install inner tie rod
    Apply the appropriate grease (supplied in kit or per manufacturer specification) to the rack threads and inner tie rod threads. Thread the inner tie rod clockwise into the steering rack by hand until snug, then torque to specification using an inner tie rod tool.
    Torque spec

    Tie Rod Nut62 Nm (46 lb-ft)
11. 11

    Complete inner boot installation
    Ensure the inner boot is properly positioned over the inner tie rod connection. Install and tighten the outer clamp of the inner boot, securing it to the small end of the boot near the inner tie rod base. Verify the boot is not twisted and has freedom to flex.
12. 12

    Install outer boot
    Slide the new outer boot over the inner tie rod, positioning it to overlap with the inner boot or seat in the designated area per the kit instructions. Install clamps on both ends of the outer boot and tighten securely. Ensure the boot has adequate slack for suspension travel.
13. 13

    Reinstall outer tie rod end
    Thread the jam nut onto the inner tie rod first. Then thread the outer tie rod end onto the inner tie rod the same number of turns recorded during removal, or match the measurement/marks made earlier. Do not tighten the jam nut yet.
14. 14

    Connect outer tie rod to knuckle
    Insert the outer tie rod end stud into the steering knuckle taper. Install the castle nut and torque to specification. Align the castle nut slots with the stud hole (tighten further if needed, never loosen). Install a new cotter pin and bend tabs to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
15. 15

    Finalize and repeat for opposite side
    Once the tie rod position is verified correct based on your measurements, tighten the jam nut securely against the outer tie rod end. Repeat steps 1-15 for the opposite side of the vehicle, replacing both boots completely.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts in a star pattern
2. Lower vehicle from jack stands to the ground
3. Torque wheel lug nuts to specification in a star pattern
4. Start engine and turn steering wheel lock-to-lock several times to verify smooth operation and proper boot flex
5. Visually inspect boots for proper seating and no binding during steering movement

Verification

• Check that all boot clamps are secure and boots are not twisted or torn
• Verify steering operates smoothly with no binding or unusual noises
• Confirm tie rod end castle nuts are properly torqued with new cotter pins installed
• Schedule a professional wheel alignment as tie rod adjustment affects toe settings
• Test drive vehicle at low speed in a safe area to confirm steering response before returning to normal operation

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