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What is wrong with my steering? Three broken racks and now shaft issue

Three years ago the shaft needed to be replaced on our 2009 Ford Flex. We noticed the power steering fluid was leaking and took it in. Fast forward to this past Dec., the same issue presented itself and low and behold, we needed another rack. 4 months later it happens again, with the dealer claiming that we must just have gotten a faulty rack in Dec. What is going on here? The mechanic said he checked the steering pump and there were no issues. Now there is significant trouble with the shaft. He lubricated it, but steering is still poor. Did the faulty rack have something to do with this? He's saying we may need a new one in the near future. The dealership sent us home twice since this third rack replacement without the issue resolved.

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@campbell12 this is a tricky one and should really be straightend ot by the dealer. There was a recall for power steering issues for the Ford flex. Discuss that with your dealer. "Ford says an intermittent electrical connection can cause the power steering to stop. That sends the steering into manual mode, making the vehicles harder to control. The company says it knows of four crashes due to the problem but no injuries.

Dealers will either update power steering control software or replace the steering gear depending on the problem with individual vehicles. A new steering gear eliminates the electrical issue." Of course we cannot know if your Flex is part of this recall, but definitely an avenue to explore.

Check on here for any recall notice if not your dealer should have the TSB for the steering repair.

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Just pinging to see how this ended up because I am in the same position, dealer replaced the rack, it was leaking in less than a month, said it was a defective rack, replaced again, and two months later, still leaking. I’m to the point where it will probably be cheaper just to trade the Flex in.

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John will be eternally grateful.
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