Steering Tie Rod Assembly problems of the 2012 Ford F-150

I hear a thunking noise under the front suspension over bumps in the road. My first reaction is it's a brand new truck. It sounds exactly like a bad sway bar link. So I took the truck to my friends mechanics garage and noticed front tires are cupped badly, an unusually wear for a new truck. We rotated the tires and checked suspension. We noticed what we thought was a bad inner tie rod cause there was loose unusual movement side to side with the tire on driver's side. So I went home and started to read on f150 forum. Com and found many people with 2011-2013 f150 year truck is having the same issue of thunkin noise. It turns out it is not tie rods, it is a bad steering rack and pinion. I read alot of information and a video of a truck that sound like mine. I have read where a service writer mentioned that 2 trucks lost steering but there was no accident and the steering racks were replaced. I have called Ford service recently and they said they know nothing about bad steering racks. Many owners of these trucks have posted in the forum that Ford knows of these so called contaminated steering racks that were made. I would like a TSB or a service bulletin that would get these bad racks off these trucks. Thank you.

The vehicle from original purchase date in October of 2012 has exhibited a knock/clunk/vibration from the front suspention and steering that transmits up through the steering column and can be felt while holding the steering wheel and heard from the frontal area of the vehicle while driving. The steering wheel is also off center to the left and vehicle seems to pull left regardless of road crown and the front two tires are feathered across the tread. The first visit to dealer at 2700 miles the dealer reset the toe as it was toe out causing uneven tire wear. The vehicle was taken to the dealer at roughly 4700 miles for the knock/clunk/vibration and uneven tire wear again and it was found that pinch bolts were loose on the steering column causing the clunk. Dealer states the uneven tire wear was due to low tire pressure. After picking up vehicle the knock/clunk/vibration is still present. With the vehicle off and turning the wheel back and forth rapidly the knock/clunk can be heard from the front of the vehicle, however the dealer states this is normal noise from the Ford epas steering rack. Asked dealer to compare to a new like vehicle on the lot. Dealer changed the subject. Sounds like faulty tie rod ends or faulty internal rack components from my past automotive experience. Owned a 2011 f150 with the same suspention and epas steering rack and the wheel was straight, and no noise was heard or vibrations felt while driving. Tires did not show uneven wear either. Dealer states I cannot compare my 2012 f150 to my 2011 f150. Dealer states an apointment is going to be set with the local field service engineer to test drive my vehicle to make a determination if any further action is to be taken. At this point the dealer is not providing any further assistance in resolving my concern. Issue has also been documented with Ford customer care.

Shortly after the purchase of this new 2012 Ford f150 ecoboost, a knocking developed that could be felt through the steering wheel. This occurred while driving straight, and could be felt and heard under normal road conditions. It doesn't have to be a bumpy road, normal road conditions this occurs. It feels like a rattle or knocking coming from the steering assembly. I brought the vehicle to the dealer for it's first oil change, and to have the knocking issue looked at on August 8, 2012. The dealer noticed the noise and their repair made was to rotate the tires. August 15, 2012 brought the truck back for the same condition. The dealer noticed the noise during the road test and contacted the Ford hotline. No repairs made. September 21, 2012 brought the truck back for the same condition. The technician could not duplicate the noise condition. No repairs made. October 25, 2012 after contacting Ford customer care center myself, they instructed me to bring the truck back in and they will replace the tie rods. Tie rods replaced on this date. November 5, 2012 brought the truck back in for the same condition. Service department refused to test drive the truck, and told me that everything is normal and "operates as designed". January 14, 2012-still have knocking/rattle condition through steering wheel.