This procedure covers removal and replacement of the outer tie rod end assembly on a 2015 Kia Forte, including separation from the steering knuckle and proper alignment preparation.

Warnings

Tools required

Parts

• Outer tie rod end assembly × 1 — Use OEM specification
• Cotter pin × 1 — Use OEM specification
• Tie rod lock nut (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands at designated lift points
4. Remove front wheel on side being serviced
5. Spray tie rod end castle nut and lock nut with penetrating oil if corrosion is present

Procedure

1. 1

   Mark tie rod position for alignment reference
   Using a paint marker, mark the position of the outer tie rod end on the inner tie rod threads. Count and record the number of exposed threads beyond the lock nut. Measure the overall length from the center of the inner tie rod ball joint to the center of the outer tie rod ball joint and record this measurement. This will help approximate alignment during reassembly.
2. 2

   Remove cotter pin from tie rod end castle nut
   Straighten the cotter pin legs using needle nose pliers. Pull the cotter pin out of the castle nut and tie rod end stud. Discard the old cotter pin as it cannot be reused.
3. 3

   Loosen tie rod end castle nut
   Using a 19mm wrench or socket, loosen the tie rod end castle nut but do not remove it completely. Leave the nut threaded on the stud by several turns to protect the threads and prevent the tie rod from falling when separated.
4. 4

   Separate tie rod end from steering knuckle
   Position the tie rod end separator tool or pickle fork between the steering knuckle and tie rod end ball joint. Strike the tool with a hammer or use the threaded separator to apply pressure until the taper releases and the ball joint pops free from the knuckle. Once separated, remove the castle nut completely and remove the tie rod end from the knuckle stud hole.
   ⚠Pickle fork tools will damage the tie rod end boot. Use only when replacing the tie rod end.
5. 5

   Loosen tie rod lock nut
   Hold the outer tie rod end with a 19mm wrench to prevent it from spinning. Using a 22mm wrench, loosen the lock nut on the inner tie rod threads. Do not remove the lock nut completely yet.
6. 6

   Remove outer tie rod end
   Count the number of turns as you unthread the outer tie rod end from the inner tie rod. Remove the outer tie rod end completely along with the lock nut. Clean the inner tie rod threads with a wire brush to remove dirt and corrosion.
7. 7

   Install new outer tie rod end
   Thread the lock nut onto the inner tie rod first, positioning it back from the end. Thread the new outer tie rod end onto the inner tie rod the same number of turns counted during removal, aligning with the paint mark made earlier. Verify the overall length measurement matches the original recorded measurement.
   ℹ️This is an approximation only. Professional alignment is still required after installation.
8. 8

   Install tie rod end to steering knuckle
   Insert the tie rod end stud into the steering knuckle hole. Install the castle nut and tighten to specification. The castle nut slots must align with the hole in the stud for cotter pin installation. If alignment is not achieved at exact torque, tighten further (do not loosen) to the next slot alignment, not exceeding 10% over specification.
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
9. 9

   Install new cotter pin
   Insert a new cotter pin through the castle nut slot and tie rod end stud hole. Bend the legs of the cotter pin over the castle nut in opposite directions to secure it. Ensure the cotter pin is fully seated and cannot back out.
10. 10

    Tighten tie rod lock nut (preliminary)
    Hold the outer tie rod end with a 19mm wrench to prevent rotation. Tighten the lock nut snug against the outer tie rod end housing, but do not torque to final specification yet. Final torque will be applied after professional wheel alignment is completed.
    ℹ️Lock nut final torque of 64 Nm (48 lb-ft) must be applied AFTER alignment adjustment is complete.
11. 11

    Reinstall wheel
    Position the wheel onto the hub and hand-thread all lug nuts. Tighten lug nuts in a star pattern while vehicle is still on jack stands to seat the wheel. Lower vehicle to the ground and torque lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. Ensure cotter pin is properly installed and secured with legs bent
2. Verify tie rod end ball joint boot is not damaged and is properly seated
3. Check that all fasteners are properly torqued per specifications

Verification

• Verify tie rod end stud moves freely in ball joint housing without binding or excessive play
• Confirm cotter pin is fully installed and secure
• Turn steering wheel full lock to lock and verify smooth operation with no binding or unusual noises
• Have vehicle professionally aligned immediately after repair, ensuring tie rod lock nut is torqued to 64 Nm (48 lb-ft) after alignment is set
• Test drive vehicle at low speed in safe area to verify steering response before normal operation

More procedures for this vehicle