This procedure covers the removal and replacement of the upper steering shaft on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, including coupling disconnection and reinstallation.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM Ford part
• Steering coupling bolt (if not reusable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn steering wheel to straight-ahead position and verify front wheels are pointing straight
3. Turn ignition off and remove key from vehicle
4. Install steering wheel locking device to prevent wheel rotation during repair
5. Disconnect negative battery cable and wait 2 minutes for airbag system to deplete
6. Remove driver's side lower dash panel and knee bolster for access to steering column
7. Remove steering column cover screws and separate upper and lower column covers

Procedure

1. 1

   Mark steering shaft alignment
   Use paint marker or masking tape to mark the exact rotational alignment between the upper steering shaft and the lower intermediate shaft at the coupling. Mark both the shaft and coupling in at least two places for redundant reference. Photograph the alignment if possible.
2. 2

   Access the coupling bolt
   Locate the steering shaft coupling bolt in the driver's footwell area where the upper shaft connects to the intermediate shaft. You may need to adjust your position or use a mechanic's mirror to see the bolt clearly. The coupling is typically located just below the dash panel.
3. 3

   Remove coupling bolt
   Using the appropriate metric socket, remove the coupling bolt that secures the upper steering shaft to the intermediate shaft. Support the shaft as you remove the bolt to prevent it from dropping. Inspect the bolt for damage or thread wear; replace if necessary.
   Torque spec

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

   Separate the coupling
   Carefully separate the upper steering shaft from the lower intermediate shaft coupling. You may need to use a flat-blade screwdriver to gently spread the coupling clamp while pulling the shafts apart. Do not force or twist excessively. Note the spline engagement depth for reassembly.
   ⚠Do not allow the lower intermediate shaft to rotate during separation as this may affect steering angle sensor calibration.
5. 5

   Remove column mounting fasteners
   Locate and remove the mounting bolts that secure the upper steering column to the dash support bracket. There are typically 2-4 bolts depending on configuration. Support the column weight as you remove the final bolt.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Disconnect electrical connectors
   Disconnect any electrical connectors attached to the steering column, including the clockspring connector, steering angle sensor connector, and any multifunction switch connectors. Press the locking tabs and carefully pull connectors straight out. Label connectors if needed for reassembly.
7. 7

   Remove upper steering shaft assembly
   Carefully lower and remove the upper steering shaft assembly from the vehicle through the driver's footwell area. Guide the shaft carefully past the dash components and wiring. Inspect the shaft for wear, binding, or damage. Check the column bearings and universal joints for smooth operation and replace the entire assembly if any component is defective.
8. 8

   Install new upper steering shaft
   Guide the new or replacement upper steering shaft assembly into position through the driver's footwell area. Align the shaft with the dash mounting bracket. Ensure the shaft orientation matches the original configuration and that no wires or hoses are pinched.
9. 9

   Reconnect electrical connectors
   Reconnect all electrical connectors to the steering column in reverse order of removal. Ensure each connector clicks fully into place and locking tabs engage properly. Verify clockspring connector is properly seated to prevent airbag issues.
10. 10

    Install column mounting bolts
    Install the steering column mounting bolts finger-tight first to ensure proper alignment. Then torque the mounting bolts to specification in a cross-pattern if multiple bolts are present. Verify the column is secure and properly positioned.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Align and connect coupling
    Align the upper steering shaft with the lower intermediate shaft using the alignment marks made during disassembly. Ensure the splines engage fully and the shafts are at the correct rotational position. The coupling should slide together with minimal force when properly aligned.
    ⚠Verify alignment marks match exactly before installing coupling bolt. Misalignment will cause steering wheel off-center condition.
12. 12

    Install coupling bolt
    Install the new or reusable coupling bolt through the coupling clamp. Ensure the bolt passes through both the coupling and the shaft properly. Torque the coupling bolt to specification. Double-check that the alignment marks still match after tightening.
    Torque spec

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

    Reinstall column covers
    Position the lower and upper steering column covers back onto the column. Ensure all clips and alignment tabs are properly seated. Install the cover screws and torque to specification. Verify covers are secure and do not interfere with column operation.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
14. 14

    Reinstall dash panels
    Reinstall the driver's side knee bolster and lower dash panel. Ensure all clips engage properly and panels are flush. Verify no wiring is pinched behind panels.

Reassembly

1. Remove steering wheel locking device
2. Reconnect negative battery cable
3. Turn ignition to ON position without starting engine and verify no warning lights remain illuminated abnormally
4. Verify steering wheel is centered when front wheels are pointing straight ahead
5. Start engine and verify electric power steering operates normally with no unusual noises

Verification

• Turn steering wheel lock-to-lock while stationary and verify smooth operation with no binding or unusual noises
• Check for proper steering wheel return to center after turning
• Test drive vehicle at low speed in safe area and verify steering response is normal and wheel is centered during straight-line driving
• Verify no steering-related warning lights are illuminated on instrument cluster
• If steering angle sensor warning appears, perform steering angle sensor calibration procedure using Ford IDS or equivalent scan tool
• Inspect coupling area for proper alignment and verify coupling bolt is tight

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