This procedure covers the replacement of the inner and outer steering rack boots on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, requiring removal of tie rod ends and rack components.

Warnings

Tools required

Parts

• Steering rack boot kit (inner and outer boots, left side) × 1 — Use OEM specification
• Steering rack boot kit (inner and outer boots, right side) × 1 — Use OEM specification
• Boot clamps (typically included in boot kit) × 4 — Use OEM specification
• Cotter pins for tie rod ends × 2 — Use OEM specification
• Grease packet (if not included with boots) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove both front wheels
6. Spray tie rod end nuts and rack mounting hardware with penetrating oil if rusted

Procedure

1. 1

   Remove tie rod end cotter pins and nuts
   Remove and discard the cotter pins from both outer tie rod end castle nuts. Using appropriate socket, loosen and remove the tie rod end nuts. Note the exact number of threads visible on each tie rod for approximate reassembly position.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
2. 2

   Separate tie rod ends from knuckles
   Using a tie rod end puller or pickle fork, separate the outer tie rod ends from the steering knuckles on both sides. Avoid damaging the tie rod end boots if they are being reused. Allow the tie rod to hang freely once separated.
3. 3

   Mark and remove inner tie rod ends
   Using paint or a marker, mark the position of the inner tie rod end jam nut relative to the outer tie rod. Count and record the number of turns as you unthread the outer tie rod end from the inner tie rod. This maintains approximate toe setting. Remove outer tie rod ends from both sides.
4. 4

   Access steering rack
   From underneath the vehicle, locate the steering rack assembly behind the front crossmember. Remove any skid plates or protective covers that obstruct access to the rack boots using appropriate socket for cover screws if present.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
5. 5

   Remove outer boot clamps
   Using boot clamp pliers or cutting pliers, remove the outer boot clamps from both inner tie rod boots (rack end boots). Note the orientation and position of the clamps for reinstallation of new clamps.
6. 6

   Remove inner boot clamps and boots
   Remove the inner boot clamps that secure the boots to the steering rack housing. Carefully slide the old boots off the inner tie rods toward the outer end. Inspect the rack for any grease leakage or damage to the rack itself.
   ℹ️If rack shows signs of fluid leakage or internal damage, rack replacement may be necessary instead of just boot replacement.
7. 7

   Clean rack components
   Using brake parts cleaner and a wire brush, thoroughly clean the inner tie rod shafts and the areas where the new boots will mount on the rack housing. Remove all old grease, dirt, and debris. Inspect inner tie rod ball joints for excessive wear or damage.
8. 8

   Install new inner boots
   Apply a light coating of grease to the rack housing mounting area. Slide the new inner boots onto the inner tie rods from the outer end, positioning them fully onto the rack housing. Ensure the boot seating groove aligns properly with the housing.
9. 9

   Pack boots with grease and secure
   Pack the interior of each boot with the recommended amount of grease (typically supplied with boot kit). Install new inner boot clamps on the rack housing end, ensuring they are properly seated in the boot groove. Tighten clamps securely using boot clamp tool.
10. 10

    Secure outer boot clamps
    Position and install the outer boot clamps on the inner tie rod end of each boot. Ensure boots are not twisted and are properly seated. Tighten outer clamps securely. Verify boots can flex without binding through full range of motion.
11. 11

    Reinstall outer tie rod ends
    Thread the outer tie rod ends back onto the inner tie rods, matching the marks made during removal and using the same number of turns recorded earlier. Tighten jam nuts hand-tight for now to allow final adjustment.
12. 12

    Reconnect tie rod ends to knuckles
    Insert the tie rod end studs into the steering knuckle tapers on both sides. Install the castle nuts and torque to specification. Install new cotter pins through the castle nut slots and tie rod stud holes. Bend cotter pin ends to secure.
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
13. 13

    Reinstall wheels and lower vehicle
    Install both front wheels and hand-tighten lug nuts in a star pattern. Lower vehicle until wheels contact ground but vehicle weight is not fully on wheels. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all boot clamps are tight and boots are not twisted or damaged
2. Verify tie rod ends are properly seated in steering knuckle tapers
3. Double-check that all cotter pins are installed and properly bent
4. Reinstall any skid plates or covers removed during access

Verification

• Turn steering wheel lock-to-lock while vehicle is on ground and verify smooth operation with no binding
• Inspect both boots visually for proper seating and no twisting or damage
• Check for any grease leakage around boot clamps
• Verify all fasteners are torqued to specification
• Test drive vehicle at low speed in safe area to verify steering response
• Schedule professional wheel alignment as toe settings will have changed

More procedures for this vehicle