🔧 Fusion - Outer Tie Rod End Replacement

This repair replaces the worn outer tie rod end, which connects the steering rack to the front wheel knuckle and helps steer your Fusion. A bad tie rod end can cause loose steering, clunking, uneven tire wear, or poor alignment.

Difficulty Level: Intermediate | Estimated Time: 1-2 hours per side

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⚠️ Safety & Precautions

• ⚠️ Work on a flat, solid surface and support your Fusion with jack stands before going under or near the wheel area.
• ⚠️ Never rely on a floor jack alone. A floor jack lifts the car; jack stands safely hold it up.
• ⚠️ The steering knuckle and brake area may have sharp edges, so wear gloves and safety glasses.
• ⚠️ Do one side at a time so you can compare the other side if needed.
• ⚠️ A wheel alignment is required after replacing a tie rod end.
• ⚠️ Battery disconnect is not required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• 19mm lug nut socket
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench
• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• Adjustable wrench
• 21mm open-end wrench
• 15mm socket
• Ratchet
• Tie rod end puller (specialty)
• Needle-nose pliers
• Paint marker
• Tape measure
• Wire brush
• Penetrating oil
• Anti-seize compound
• Mechanic gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Outer tie rod end - Qty: 1 per side
• New tie rod end castle nut or prevailing torque nut - Qty: 1 per side
• New cotter pin - Qty: 1 per side, if equipped with castle nut
• Wheel alignment service - Qty: 1

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📋 Before You Begin

• Park your Fusion on level ground, shift to Park, and set the parking brake.
• Place wheel chocks behind the rear wheels to keep the car from rolling.
• Turn the steering wheel slightly so the tie rod end you are replacing is easier to reach.
• Spray the tie rod jam nut and tie rod end stud with penetrating oil and let it soak for a few minutes.
• A jam nut is the locking nut on the inner tie rod that keeps the outer tie rod end from turning.
• Before removing the old tie rod end, mark and measure its position. This helps keep the alignment close enough to drive to an alignment shop.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Wheel Lug Nuts

• Use a 19mm lug nut socket and 1/2-inch drive breaker bar to loosen the front wheel lug nuts about half a turn.
• Do this while the tire is still touching the ground so the wheel does not spin.
• Tip: Do not remove the lug nuts yet.

Step 2: Lift and Support the Front of the Vehicle

• Use a floor jack at the front jacking point to lift your Fusion high enough for the tire to clear the ground.
• Place jack stands under the proper front support points.
• Slowly lower the vehicle onto the jack stands.
• Gently shake the vehicle by hand to confirm it is stable before removing the wheel.

Step 3: Remove the Front Wheel

• Use the 19mm lug nut socket and ratchet to remove the loosened lug nuts.
• Remove the wheel and set it flat under the side of the vehicle as an extra safety backup.

Step 4: Mark the Tie Rod Position

• Use a wire brush to clean the threads where the outer tie rod end meets the jam nut.
• Use a paint marker to mark the position of the jam nut on the threads.
• Use a tape measure to measure from the center of the tie rod end stud to a fixed point on the inner tie rod, and write the measurement down.
• Tip: This helps preserve steering alignment temporarily.

Step 5: Loosen the Jam Nut

• Hold the outer tie rod end steady with an adjustable wrench.
• Use a 21mm open-end wrench to loosen the jam nut about one turn.
• Do not move the jam nut far from your paint mark.

Step 6: Remove the Tie Rod End Nut

• If your tie rod end uses a cotter pin, use needle-nose pliers to straighten and remove the cotter pin.
• Use a 15mm socket and ratchet to remove the tie rod end nut from the steering knuckle.
• The steering knuckle is the metal part that the wheel hub and tie rod connect to.

Step 7: Separate the Tie Rod End from the Steering Knuckle

• Install the tie rod end puller over the tie rod end stud and steering knuckle.
• Tighten the tie rod end puller with the correct drive tool until the stud pops loose from the knuckle.
• Do not hit the steering knuckle hard with a hammer, because that can damage nearby parts.
• Tip: The pop sound is normal.

Step 8: Count Turns and Remove the Old Tie Rod End

• Use your hand and an adjustable wrench if needed to unscrew the old outer tie rod end from the inner tie rod.
• Count the exact number of turns it takes to remove it.
• Write the number down and compare it with your measurement from Step 4.
• Tip: Count half-turns if needed.

Step 9: Install the 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 hand the same number of turns counted during removal.
• Use the tape measure to verify the new tie rod end is close to the original measurement.
• Keep the jam nut near the original paint mark.

Step 10: Attach the Tie Rod End to the Steering Knuckle

• Insert the new tie rod end stud into the steering knuckle by hand.
• Install the new nut by hand first to avoid cross-threading.
• Use a 15mm socket and 1/2-inch drive torque wrench to tighten the tie rod end nut to Torque to 48 Nm (35 ft-lbs).
• If equipped with a castle nut, continue tightening only enough to align the cotter pin hole, then install a new cotter pin with needle-nose pliers.

Step 11: Tighten the Jam Nut

• Hold the new outer tie rod end steady with an adjustable wrench.
• Use a 21mm open-end wrench to tighten the jam nut against the outer tie rod end.
• Torque the jam nut to Torque to 55 Nm (41 ft-lbs) if your torque wrench and wrench adapter can fit correctly.
• If you cannot fit a torque wrench, tighten the jam nut firmly with the 21mm open-end wrench, then have it checked during the alignment.

Step 12: Reinstall the Wheel

• Place the wheel back onto the hub.
• Install the lug nuts by hand first.
• Use the 19mm lug nut socket and ratchet to snug the lug nuts in a star pattern.

Step 13: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack to lift the vehicle slightly off the jack stands.
• Remove the jack stands.
• Lower the vehicle fully to the ground with the floor jack.
• Use a 19mm lug nut socket and 1/2-inch drive torque wrench to tighten the lug nuts in a star pattern to Torque to 135 Nm (100 ft-lbs).

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✅ After Repair

• Turn the steering wheel lock-to-lock while parked and listen for binding, popping, or rubbing.
• Test drive slowly at first. The steering wheel may be off-center until alignment is completed.
• Schedule a professional front-end alignment immediately after the repair.
• After 25-50 miles, recheck the lug nut torque with a 19mm lug nut socket and 1/2-inch drive torque wrench to Torque to 135 Nm (100 ft-lbs).
• If the vehicle pulls hard, the steering wheel is far off-center, or stability control warnings appear, stop driving and have the alignment checked.

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💰 DIY vs Shop Cost

Shop Cost: $220-$420 per side including parts, labor, and alignment check

DIY Cost: $35-$90 per side for parts only, plus alignment

You Save: $120-$250 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.8-1.3 hours per side, plus alignment time.

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🎯 Ready to get started?

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