This procedure covers the removal and installation of the tie rod assembly on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including outer tie rod ends and adjustment for proper alignment.

Warnings

Tools required

Parts

• Tie rod end assembly (left or right as needed) × 1 — Use OEM specification
• Cotter pins × 2 — 2mm x 25mm
• Anti-seize compound × 1 — Copper-based

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen wheel lug nuts on the side being serviced while vehicle is still on ground
3. Raise and support vehicle with jack stands at appropriate jacking points on frame rail
4. Remove wheel and tire assembly completely
5. Spray tie rod end taper and jam nut threads with penetrating oil and allow to soak for 10-15 minutes
6. Verify you have the correct replacement tie rod assembly for left or right side

Procedure

1. 1

   Mark tie rod position for reference
   Before loosening any components, use a paint marker to mark the threaded position of the outer tie rod end on the inner tie rod threads. Count and record the number of exposed threads between the jam nut and tie rod end. Measure the overall length of the tie rod assembly from center of ball stud to inner tie rod mounting point. These measurements will help restore approximate toe setting.
2. 2

   Remove outer tie rod end cotter pin and castle nut
   Straighten and remove the cotter pin from the tie rod end castle nut using pliers. Discard the old cotter pin. Using a wrench, loosen but do not fully remove the tie rod end castle nut. Leave the nut threaded on 2-3 turns to protect the threads and prevent the knuckle from dropping when the taper releases.
3. 3

   Separate tie rod end from steering knuckle
   Using a tie rod end separator or pickle fork, strike the tool to break the taper between the tie rod end ball stud and steering knuckle. Apply force to the side of the knuckle boss, not directly on the tie rod boot. Once the taper releases, remove the castle nut completely and pull the tie rod end out of the knuckle. If using a pickle fork, note that the dust boot may be damaged and require replacement.
   ⚠Keep hands and body clear when striking the separator tool. The taper may release suddenly.
4. 4

   Loosen tie rod jam nut
   Using two wrenches, hold the outer tie rod end stationary while loosening the jam nut (lock nut) that secures it to the inner tie rod. The jam nut threads onto the inner tie rod and locks the outer tie rod end in position. Do not remove the jam nut completely yet.
5. 5

   Remove outer tie rod end
   Count the number of turns as you unthread the outer tie rod end from the inner tie rod shaft. Record this number for installation reference. Once the outer tie rod end is removed, inspect the inner tie rod threads and clean with a wire brush if necessary. Inspect the inner tie rod boot for damage or leaks.
6. 6

   Install new outer tie rod end
   Apply a light coat of anti-seize compound to the inner tie rod threads. Thread the new outer tie rod end onto the inner tie rod by the same number of turns counted during removal, or align with the paint mark made earlier. This provides an approximate starting point for alignment. Do not tighten the jam nut yet.
7. 7

   Install tie rod end to steering knuckle
   Insert the tie rod end ball stud into the steering knuckle taper. Ensure the taper surfaces are clean and free of debris. Install the tie rod end nut and tighten to specification. The castellations on the nut must align with the hole in the ball stud for cotter pin installation.
   ⚠If castle nut slots do not align with cotter pin hole at specified torque, tighten nut further up to 1/6 turn (60 degrees) maximum to achieve alignment. Never loosen the nut to align the cotter pin hole.
   Torque spec

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

   Install new cotter pin
   Insert a new cotter pin through the castle nut and tie rod end ball stud hole. Bend the ends of the cotter pin in opposite directions to secure it. Trim excess length if necessary, but ensure the pin cannot work loose. Verify the cotter pin is fully seated and secure.
9. 9

   Perform preliminary toe check
   With the steering wheel centered, measure from a fixed reference point on the frame to the front and rear edges of the wheel rim on both sides. Compare left and right measurements to verify approximate toe symmetry. Make small adjustments to the tie rod length if grossly misaligned, loosening the jam nut, adjusting the tie rod end, and re-tightening.
10. 10

    Tighten tie rod jam nut
    Hold the outer tie rod end stationary with one wrench while torquing the jam nut (lock nut) to specification with a torque wrench. Ensure the tie rod end does not rotate during this process, which would change the toe setting. Verify the tie rod end remains at the marked position after tightening.
    ℹ️This jam nut torque is applied before final alignment. The nut should be verified after professional alignment is completed.
    Torque spec

    Tie Rod Lock Nut78 Nm (58 lb-ft)
11. 11

    Reinstall wheel and tire
    Position the wheel onto the hub and start all lug nuts by hand. Using a torque wrench and star pattern, tighten the wheel lug nuts to specification in three progressive steps: first to 50 Nm, then 100 Nm, then final torque.
    Torque spec

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

    Lower vehicle and perform final checks
    Carefully lower the vehicle to the ground. With the vehicle weight on the suspension, perform a final torque verification on the wheel lug nuts. Turn the steering wheel lock-to-lock slowly to verify full range of motion without binding or interference. Check that the steering wheel returns to center smoothly.

Reassembly

1. Ensure all fasteners are torqued to specification and verified with a calibrated torque wrench
2. Verify cotter pins are properly installed and secured at all tie rod end connections
3. Confirm no tools or parts were left in the wheel well or suspension area
4. The tie rod jam nut torque specification is applied after final alignment is complete

Verification

• Test drive vehicle at low speed in a safe area to verify steering response and that the vehicle tracks straight
• Listen for any unusual noises from the tie rod area during steering input
• Verify steering wheel is approximately centered when driving straight (minor deviation is normal before alignment)
• Schedule a professional four-wheel alignment immediately after completing this repair
• After alignment, verify the tie rod jam nut remains torqued to 78 Nm (58 lb-ft)
• Re-check wheel lug nut torque after 50-100 miles of driving

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