This procedure covers the complete removal and replacement of the electric power steering rack on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Power steering rack assembly × 1 — Use OEM specification
• Steering rack mounting hardware kit × 1 — Use OEM specification
• O-rings for pressure line fitting × 1 — Use OEM specification
• Tie rod end cotter pins × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
3. Turn steering wheel to center position and lock in place using steering wheel lock or remove ignition key
4. Raise front of vehicle and secure on jack stands at frame contact points
5. Remove both front wheels

Procedure

1. 1

   Remove front skid plate and splash shields
   Remove the front skid plate fasteners and lower the skid plate from the vehicle. Remove any front splash shields or underbody covers that obstruct access to the steering rack and front subframe area.
2. 2

   Disconnect tie rod ends
   Remove the cotter pins from both tie rod end castle nuts. Using the appropriate socket, loosen the tie rod end nuts. Use a tie rod separator or pickle fork to separate the tie rod ends from the steering knuckles. Remove the nuts completely and set tie rod ends aside.
   Torque spec

   Tie Rod End Nut62 Nm (46 lb-ft)
3. 3

   Mark and disconnect steering shaft coupling
   Working from inside the cabin or through the firewall access, locate the steering shaft coupling bolt at the base of the steering column where it connects to the steering rack input shaft. Mark the alignment between the shaft and coupling with paint or a marker. Remove the coupling bolt and separate the steering shaft from the rack. Ensure the steering wheel remains locked in the center position.
   ⚠Failure to keep the steering wheel centered during this procedure can damage the airbag clockspring, requiring expensive replacement.
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
4. 4

   Disconnect electrical connectors
   Locate the electrical connector(s) on the electric power steering rack assembly. Press the release tabs and disconnect all electrical connectors. Ensure connectors are positioned away from the rack to prevent damage during removal.
   ℹ️Some models may have multiple connectors for the electric motor and position sensors. Label connectors if needed for reassembly.
5. 5

   Support front subframe
   Position a transmission jack or adjustable jack stand under the front subframe to support its weight. The subframe may need to be lowered slightly to provide clearance for rack removal on some configurations.
   ⚠Ensure jack is positioned securely on the subframe and will not slip during loosening or lowering operations.
6. 6

   Remove steering rack mounting bolts
   Locate the steering rack mounting bolts that secure the rack to the front subframe or crossmember. There are typically two main mounting bolts. Remove these bolts while supporting the rack assembly to prevent it from falling.
   Torque spec

   Rack Mounting Bolts117 Nm (86 lb-ft)
7. 7

   Lower and remove steering rack
   Carefully maneuver the steering rack assembly out of its mounting position. You may need to rotate or angle the rack to clear the subframe and other components. Lower the rack assembly down and out through the front or side of the vehicle, depending on clearance. On some configurations, slightly lowering the subframe 1-2 inches may be necessary for clearance.
   ⚠The electric power steering rack assembly is heavy. Use proper lifting techniques or have an assistant help guide the rack during removal.
8. 8

   Transfer components to new rack
   If the new rack does not come with tie rod ends installed, transfer the outer tie rod ends from the old rack to the new rack. Count and record the number of threads exposed on the old tie rod ends before removal to maintain approximate alignment. Clean threads with a wire brush before installation.
   ℹ️Matching the tie rod thread position will provide a close approximation of the previous alignment, but a professional alignment is still required after this repair.
9. 9

   Install new steering rack
   Carefully lift the new steering rack assembly into position, maneuvering it through the same path used during removal. Align the rack mounting holes with the subframe or crossmember mounting points. Start both rack mounting bolts by hand to ensure proper thread engagement before tightening.
10. 10

    Torque rack mounting bolts
    Using a calibrated torque wrench, tighten the rack mounting bolts to specification in an alternating pattern to ensure even seating of the rack assembly.
    Torque spec

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

    Raise subframe if lowered
    If the subframe was lowered for clearance, raise it back to its original position and reinstall any subframe mounting bolts that were removed. Torque subframe bolts to specification per service manual.
12. 12

    Reconnect steering shaft coupling
    Align the marks made during disassembly on the steering shaft and rack input shaft. Ensure the steering wheel is still in the centered position. Install the coupling bolt and torque to specification. Verify the coupling is fully seated and there is no play in the connection.
    ⚠Misalignment of the steering shaft coupling will result in an off-center steering wheel and potential handling issues.
    Torque spec

    Coupling Bolt39 Nm (29 lb-ft)
13. 13

    Connect electrical connectors
    Reconnect all electrical connectors to the power steering rack assembly. Ensure each connector clicks fully into place and the locking tabs are engaged. Route wiring away from any moving or hot components.
14. 14

    Reconnect tie rod ends
    Insert the tie rod end ball studs into the steering knuckle tapers. Install the tie rod end nuts and torque to specification. Install new cotter pins through the castle nuts and bend the pins to lock them in place.
    ℹ️Never back off a castle nut to align cotter pin holes. If necessary, tighten the nut slightly more (up to 1/6 turn maximum) to align the next castle slot.
    Torque spec

    Tie Rod End Nut62 Nm (46 lb-ft)
15. 15

    Reinstall skid plates and wheels
    Reinstall all front splash shields and the front skid plate with their original fasteners. Install both front wheels and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground and torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Reconnect the negative battery terminal
2. Start the engine and turn the steering wheel lock to lock several times to initialize the electric power steering system
3. Check for any warning lights on the instrument cluster related to power steering
4. The steering system may require initialization or calibration using a diagnostic scan tool depending on vehicle configuration

Verification

• Start the vehicle and verify the power steering warning light is not illuminated
• Turn the steering wheel through its full range of motion and verify smooth operation with no binding or unusual noises
• Verify the steering wheel is centered when the wheels are pointing straight ahead (within 1-2 degrees)
• Test drive the vehicle at low speed in a safe area to confirm proper steering function and returnability
• Have the vehicle professionally aligned as soon as possible after completing this repair, as tie rod positions will affect alignment angles
• Monitor for any warning lights or steering issues during the first several drives after the repair

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