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

Warnings

Tools required

Parts

• Inner tie rod end × 1 — Use OEM specification
• Tie rod lock nut × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Tie rod boot/bellows (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support with jack stands on frame rails
4. Remove front wheel on side being serviced
5. Turn steering wheel to position tie rod for easier access (turn opposite direction of side being serviced)
6. Spray all tie rod threads and connections with penetrating oil and allow to soak

Procedure

1. 1

   Mark tie rod position
   Before disassembly, measure and record the distance from the outer tie rod end to the inner tie rod housing, or make alignment marks with paint marker on the threads where the outer tie rod meets the inner tie rod. Count and record the number of exposed threads. This will help achieve a close initial toe setting.
2. 2

   Remove outer tie rod end from knuckle
   Remove the cotter pin from the outer tie rod end castle nut. Loosen but do not fully remove the tie rod end nut. Use a tie rod separator or pickle fork to break the taper connection between the tie rod end and steering knuckle. Once separated, remove the nut completely and pull the tie rod end from the knuckle.
   ⚠Leave the nut threaded on a few turns before using separator to prevent sudden release and potential injury.
3. 3

   Loosen tie rod lock nut
   Using an 18mm wrench, loosen the jam nut (lock nut) that secures the outer tie rod to the inner tie rod. Do not remove it completely yet. This nut is located where the outer tie rod threads onto the inner tie rod end.
4. 4

   Remove outer tie rod
   Unthread the outer tie rod end from the inner tie rod by turning it counterclockwise. Count the number of full rotations required to remove it and record this number. Remove the lock nut from the inner tie rod threads.
5. 5

   Access inner tie rod boot
   Pull back or cut the steering rack boot/bellows to expose the inner tie rod connection to the steering rack. If the boot is in good condition and has a clamp, loosen the clamp and slide it back. Inspect the boot for damage and replace if cracked or torn.
6. 6

   Remove inner tie rod end
   Using an inner tie rod removal tool or a large adjustable wrench on the flats of the inner tie rod, unthread the inner tie rod from the steering rack. Turn counterclockwise to remove. The inner tie rod may be very tight and require significant force. Some designs may have a staked lock washer that needs to be straightened first.
   ⚠Support the steering rack to prevent rotation during removal. Do not allow the rack to twist excessively.
7. 7

   Prepare new inner tie rod
   Clean the threads on the steering rack with a wire brush. Inspect the rack threads for damage. Compare the new inner tie rod to the old one to verify correct part. Apply a small amount of medium-strength thread locker to the first few threads of the new inner tie rod if not pre-applied.
8. 8

   Install new inner tie rod
   Thread the new inner tie rod into the steering rack by hand until it bottoms out, then tighten to specification using the inner tie rod tool. Ensure the tie rod is fully seated against the rack shoulder before final torque. Note: Inner tie rod torque is typically very high (70-100 lb-ft range). Use the Tie Rod Lock Nut specification as reference for final assembly after alignment.
9. 9

   Install steering rack boot
   Slide the steering rack boot back into position over the inner tie rod connection. Ensure the boot is fully seated in its groove on both the rack housing and the inner tie rod. Install and tighten the boot clamps securely. Check that the boot is not twisted or damaged.
10. 10

    Install outer tie rod end
    Thread the lock nut onto the inner tie rod threads first. Then thread the outer tie rod onto the inner tie rod the same number of rotations recorded during removal, or to the alignment marks made earlier. Do not tighten the lock nut yet.
11. 11

    Connect outer tie rod to knuckle
    Insert the outer tie rod end stud into the steering knuckle. Install the castle nut and torque to specification. The castle nut slots must align with the cotter pin hole. If needed, tighten further (never loosen) to achieve alignment. Install a new cotter pin and bend the ends to secure.
    Torque spec

    Tie Rod End Nut62 Nm (46 lb-ft)
12. 12

    Install wheel and lower vehicle
    Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground. Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Do not torque the tie rod lock nut to final specification until after the front-end alignment is completed
2. After alignment, torque the tie rod lock nut to 78 Nm (58 lb-ft)
3. Verify all fasteners are tightened to specification and all cotter pins are properly installed
4. Test drive vehicle in a safe area to verify steering feel and response before returning to service

Verification

• Steering wheel should return to center smoothly without binding
• No unusual noises from the front suspension during steering input
• Vehicle tracks straight when driving on level road with hands lightly on steering wheel
• Professional front-end alignment must be performed to set toe, camber, and caster to factory specifications
• Verify proper steering rack boot installation with no leaks or damage
• Confirm tie rod lock nut is torqued after alignment is complete

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