This procedure covers the removal and replacement of the outer tie rod end on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, requiring a front-end alignment upon completion.

Warnings

Tools required

Parts

• Outer tie rod end × 1 — Use OEM specification or quality aftermarket
• Cotter pin × 1 — Standard tie rod cotter pin

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on the ground
3. Raise and support vehicle on jack stands at the front frame rails
4. Remove the front wheel on the side being serviced
5. Spray penetrating lubricant on tie rod end castle nut and tie rod lock nut threads, allow to soak

Procedure

1. 1

   Mark tie rod position for reference
   Before loosening anything, use a marker or paint pen to mark the position of the outer tie rod end on the inner tie rod threads. Also measure and record the exposed thread length between the lock nut and the outer tie rod end. This helps maintain approximate alignment during installation.
2. 2

   Remove 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 22mm wrench, remove the castle nut that secures the tie rod end to the steering knuckle. Do not reuse this nut if it shows any thread damage.
3. 3

   Separate tie rod end from knuckle
   Using a tie rod end separator tool or pickle fork, separate the tie rod end taper from the steering knuckle. Position the separator between the tie rod end and knuckle, then strike or compress the tool to break the taper free. Avoid hammering directly on the tie rod end stud as this can damage the threads.
   ⚠Pickle fork tools will damage the tie rod end boot; only use if replacing the tie rod end
4. 4

   Loosen tie rod lock nut
   Using a 19mm wrench, loosen the tie rod lock nut that secures the outer tie rod end to the inner tie rod. Do not remove it completely yet. This nut locks the outer tie rod in position for alignment.
5. 5

   Remove outer tie rod end
   While holding the inner tie rod steady with another wrench if needed, thread the outer tie rod end counterclockwise off the inner tie rod. Count the number of turns required for removal and note this for installation reference. Remove the lock nut from the old tie rod end.
6. 6

   Clean and inspect inner tie rod threads
   Use a wire brush to clean the threads on the inner tie rod. Inspect threads for damage or excessive wear. Check the inner tie rod boot for tears or leaks. If the boot is damaged, the inner tie rod should also be replaced.
7. 7

   Install lock nut on new tie rod end
   Thread the lock nut onto the new outer tie rod end so it is positioned near the base, leaving room to thread onto the inner tie rod. Ensure the new tie rod end threads match the old part and are the correct left or right-hand thread direction.
8. 8

   Thread new outer tie rod end onto inner tie rod
   Thread the new outer tie rod end clockwise onto the inner tie rod to approximately the same position as marked earlier, using the reference marks and turn count. Thread it to approximately the same exposed thread length as measured during disassembly. Do not fully tighten the lock nut yet.
9. 9

   Install tie rod end into steering knuckle
   Insert the tie rod end stud into the steering knuckle taper. Ensure the taper seats properly and the stud is fully inserted through the knuckle bore. Install the castle nut and tighten to specification. The castle nut slots must align with the cotter pin hole.
   ⚠If castle nut slots do not align with cotter pin hole at proper torque, tighten further to next slot alignment - never loosen to align
   Torque spec

   Tie Rod End Nut62 Nm (46 lb-ft)
10. 10

    Install new cotter pin
    Insert a new cotter pin through the castle nut and tie rod end stud. Bend the cotter pin ends properly to secure it in place. The cotter pin must be fully seated and bent to prevent the castle nut from loosening.
11. 11

    Preliminary tighten tie rod lock nut
    Using a 19mm wrench, snug the tie rod lock nut against the outer tie rod end body. Do not torque to final specification yet - this will be done after the vehicle receives a professional alignment. Apply medium-strength thread locker if desired.
    ℹ️Final torque of lock nut to 78 Nm (58 lb-ft) must be performed after alignment to lock the final toe adjustment
12. 12

    Reinstall wheel
    Mount the wheel back onto the hub and hand-thread all lug nuts. Lower the vehicle until the tire just contacts the ground to prevent wheel rotation. Torque the wheel lug nuts in a star pattern to specification.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Fully lower the vehicle to the ground after wheel installation is complete
2. Perform a visual inspection of the tie rod end installation to ensure the cotter pin is properly installed and all connections are secure
3. Test steering wheel center position and compare to pre-repair condition

Verification

• Verify the tie rod end castle nut is torqued properly and the cotter pin is correctly installed and bent
• Check that there is no excessive play or looseness in the tie rod end connection by attempting to move the tie rod by hand
• Ensure wheel lug nuts are torqued to specification in a star pattern
• Schedule immediate front-end alignment with a qualified alignment shop - toe setting will be significantly altered
• After alignment is complete, the tie rod lock nut must be torqued to final specification of 78 Nm (58 lb-ft)
• Road test vehicle at low speed in a safe area to verify steering response and center position before normal driving

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