There's no point in looking for other causes just because they won't give you a printout.
I always made two printouts of my alignments, one that I kept and one that I placed on the passenger front seat, with the items highlighted that I changed or adjusted. Most shops don't take the time to make printouts, and in your case, the information has left the alignment computer as soon as they set it up for the next car. They can't go back and make a printout for any previous alignment, only the one that is currently connected to the equipment.
Also, I don't know of anyone else who makes a printout to keep for themselves, like I did. I was very well known at my dealership to take longer than "flat rate" times to complete jobs, but I was also well known to have very few "comebacks", or complaints. In case a customer did have a complaint, or even just a question, I had my copy of the printout to refer to and use for explanations. After ten years, my stack of printouts was over ten inches high.
What I was hoping to not see was that you did the alignment yourself. Many of us used to do the "race car method" that included strings and tape measures. That can work for some racing applications, but I can cause a front-wheel-drive minivan to have a noticeable pull by increasing "camber" on one front wheel by 0.06 degrees. That's less than 1/64" on a tape measure. There's no way a competent do-it-yourselfer can get that accurate, regardless of how they take the readings.
So the good news is the alignment was done with an alignment computer, but as I explained previously, we don't know the specialist's experience level or commitment to doing a quality job. You won't find anyone to go so far overboard as I did, but the mechanic has to be conscientious and experienced to know how to interpret the readings and to know what to adjust. The only thing I have to go on in this regard is whether a test drive was performed. If not, why not, and if it was, why wasn't the pull noticed? You wouldn't have surgery at a hospital without some kind of follow-up care later. That test drive is the follow-up care to prove the alignment was done properly.
I gotta stop here and point out one thing I forgot. That is to take the vehicle back to the shop that did the alignment. If you do nothing, the mechanic could assume whatever he did or whatever values he set the adjustments to worked out okay and you're happy. He will remember that and do the same thing on the next model like yours. That could end up with multiple unsatisfied customers who spread negative word-of-mouth advertising. Everyone is better off if you return and explain what's wrong. Also, no shop owner wants someone working for him who can't be counted on to do quality work. If one person keeps getting multiple complaints, he is either going to be assigned to other types of jobs, or he may be asked to find a job at some other shop. You're helping make it in his best interest to take the time to do quality work.
Another common alignment issue is the design of some adjustment methods leaves them susceptible to slipping later, especially when hitting bumps or potholes. On most models, due to the geometric relationship of the parts, a slipped adjustment will also cause the steering wheel to go off-center. This can be confusing, but an off-center steering wheel is very different from a steering wheel that is turned to one side because you're fighting against a pull the other way. This is where experience comes in when performing an initial test drive before the alignment is started. Most of us don't do that one.
The biggest issue has been a sore point with Ford alignment specialists since the mid 1980s. That is the engineers didn't see fit to design in a method for adjusting camber. This started with the Escort that came with extremely high camber that caused the front tires to wear out in 15,000 miles, and there was no way to fix it.
"Camber" is the inward, (negative), or outward, (positive), tilt of the wheel, as viewed from in front or in back of the vehicle. For reference. a wheel standing perfectly straight up and down is 0.00 degrees. If you could imagine a wheel tipped out so far on top that it is laying flat on the ground, that would be 90.00 degrees. Most cars call for up to 0.75 degrees, which is getting pretty high, but it is needed to achieve best tire wear and it places the vehicle's weight right over the wheel bearing to lower stress on those parts. (The Escorts were built with just under 2 1/2 degrees camber which was easily noticeable when following them down the road. It also caused the outer edges of the tread to wear out very quickly.
The first image below shows the alignment specs for your model. Front camber is shown as -0.03 degrees, which, for all practical purposes, is perfectly straight up and down. That value is very respectable, but it's the tolerance of 0.75 degrees that is a heart breaker, (blue arrows).
First let me explain more about camber. Back in the days of old heavy rear-wheel-drive cars, a common specification for camber was 0.50 degrees. On top of that, we either made the left wheel 1/4 degree higher or the right wheel 1/4 degree lower, to offset "road crown". That is the slant of the road surface so water runs off. Without that extra 1/4 degree difference, the car would drift to the right on almost all roads and highways. If we leave camber perfectly equal on both sides, the same road crown offset can be achieved by increasing "caster" on the right wheel by 1/2 degree, or by lowering it 1/2 degree on the left wheel.
A pair of tires wants to pull in the direction of the one with the higher camber value. OR;
A pair of tires wants to pull in the direction of the one with the lower caster value.
To say that another way, camber has twice the effect on pulling as does caster. Now I have to add an important comment. With front-wheel-drive cars and minivans, a difference in caster, even a big one, has no effect on pulling. In all the classes I've attended or taught, no one has ever been able to explain why, but it's only true on those models. That means a pull has to be corrected by adjusting camber on one or both front wheels.
The second image shows the available adjustment instructions for your model, and front camber is not listed. That is a major shortcoming that Ford is very well known for. Their answer, if camber needs to be corrected, is to replace bent parts. I won't share what my friend at the local Ford dealership does to correct pulls, but it does keep his customers satisfied, for now, until other parts wear out prematurely. (One trick is to let some air out of one tire).
I apologize if some of this sounds technical, but my reason for describing these things has to do with the rest of the specifications. Remember, we always want camber to be slightly higher on the driver's side. Besides the exact spec., they allow a tolerance of 0.75 degrees either way, (blue arrows), on each front wheel. That means camber on the left wheel could be -0.50 degrees and still be in specs. If all an inexperienced alignment mechanic knew to look at was the color of that reading on the computer screen, it would be in green, meaning it's okay. That tire now wants to pull to the right by quite a bit. Likewise, the right wheel could be set to positive 0.50 degrees and be in specs, and in green. It will also cause a hard pull to the right. This is a case of there's a total difference of 1.00 degree pull to the right and all the numbers on the screen are green. We can never go just by the color of the numbers. We have to understand what each tire will want to do, but we have to look at both of them together.
A Ford instructor explained this in more detail, and it can apply to other manufacturers. They know a tolerance of 0.75 degrees is too much, but they're relying on our experience to know that and to not take advantage of it. We still want to get those adjustments as close as possible to perfect. The reason for publishing those very high tolerance values is as long as a car's numbers fall within that range, they will not pay the dealer to perform an alignment under warranty. That means it's up to the car owner to figure out the solution and to pay for it after the car is out of warranty. That's an extremely common trick GM likes to pull.
Related to this, every alignment computer has a button to "reduce tolerances" that we can use. That doesn't change any important numbers. All it does it force us to get an adjustment closer to perfect before it turns green. Even that can still leave us with a pull if we don't understand what those numbers are telling us.
That brings me back to the adjustments. I don't have an explanation as to why they don't provide a camber adjustment, but you will also run into that on many import models. The third image shows how they want us to correct a pull. That is to replace one or both upper control arms with ones that are offset a little to increase caster pull against the pull. Remember, caster on most vehicles doesn't cause a pull, and on those models where it does, caster only has half the effect on a pull as does camber. If both arms are replaced, we can gain or lose 0.80 degrees of caster pull which equates to a change of 0.40 degrees of camber pull. While that can be significant, what if it isn't enough?
The next problem is the mechanic has to perform the alignment, determine the need for one or both replacement control arms, order them, have you come back a second time to have those parts installed, then align the car a second time. It's even likely the dealer won't have those parts in stock. Ford is also famous for not having replacement parts available for vehicles over three years old. If you go to an auto parts store, how do you know if you're getting an aftermarket part that is like the original or it has that offset built in? This is usually a one-time modification, usually done under warranty, and even then the parts usually have to be special-ordered. In other words, after this many years, there may be no way to correct camber.
To address your question about worn parts, yes, there are ball joints, tie rod ends, and control arm bushings that must be inspected. Those are responsible for holding the wheel solidly in alignment. Ford had way more than their share of ball joints and tie rod ends that separated, leading to loss of control and crashes than all other manufacturers combined, but that hasn't been such an issue since the early 2000s. A separated part can happen on any vehicle which is why a steering and suspension inspection once every year or two is a good idea. Some parts can get a quick once over during other routine services such as oil changes. There's two things you can watch for yourself. One is a clunk or squeak, usually occurring over bumpy roads. The other is to keep an eye on tire wear patterns. This article has some dandy information:
https://www.2carpros.com/articles/how-car-tires-work
The problem with tire wear is it can take a long time to show up. Also, there can be parts worn enough to be dangerous while nothing is seen with tire wear. Also understand not all clunks are caused by something that can turn dangerous, but they can be annoying.
Except for extremely rare instances, steering gears won't cause a pull. Their two most common problems are power steering fluid leaks and "morning sickness", which is our term for loss of power steering assist first thing in the morning, that goes away minutes after the fluid warms up. The clue is the loss of power assist always occurs when turning in just one direction first, then the other way weeks later. This was a perfect example of where GM knew the solution, but performed a quick fix to get the cars out of their 50,000 mile warranty, then when the problem returned a little while later, it was up to the owners to pay for the proper and permanent repair. That design defect still didn't result in a pull.
Every alignment must start with this inspection of parts and with reading the tire wear. If bad tire wear is seen, you had better find a cause and fix it first. No conscientious mechanic will take your money and do an alignment if there's worn parts because we know those parts will not hold the wheels in alignment. Most worn parts can be replaced by a competent do-it-yourselfer, especially when you have one of us to "hold your hand" and offer advice or post instructions from the service manual. When you prefer to have the work done by a professional, we can help with parts choices, questions to ask, or specific services to request.
You didn't say if anything was done after my first reply, specifically, if the tires were switched side to side on the front. When you take the vehicle back, there should be no argument about rechecking the alignment. We do make mistakes at times, hard as that may seem to believe, and we deserve the chance to make it right. Most shops will have at least a 30-day warranty so there should be no additional charge to you. The exception would be if they find a worn part. If that was missed on the last visit, they will often offer to replace it with a discount for "customer satisfaction", but there should be no charge to redo the alignment. At the dealership I worked for, they would not charge you if I switched the front tires, and I didn't even have to tell anyone I did that, or any other service that solved what appeared to be my alignment problem. As long as it got handled, everyone was happy.
Control arm bushings can wear and cause a pull too, but it's more common to run into a clunk first. Those used to last the life of the vehicle, but with smaller and lighter cars today, those bushings are made from softer rubber compounds to absorb shock, so they deteriorate faster. Another common symptom of a worn bushing is the pull may change direction, often surprising the driver, when braking. The forces change between braking and acceleration on suspension parts causing them to shift position. That can change caster and camber momentarily on the affected wheel.
Worn tie rod ends are the easiest to spot when the tire is off the ground. Years ago, when walking past a Ford Escort or Tempo on a hoist, I couldn't stop myself from grabbing the front tires and tugging them lightly left and right. Nine out of ten times I found at least one that was sloppy and ready to fall apart. The originals lasted very little past 15,000 miles. We used to joke if we found that tenth one that didn't have slop in a tire rod end, they must have just been replaced within the past few weeks. We used to call them "killer cars" due to how many came in on tow trucks with the front wheels steering in two different directions. Thank goodness those days are gone.
For my final comment of value, I mentioned that caster can also be used to offset road crown. If you look at the red arrows in the first image, you'll see they're specifying slightly higher caster on the right front wheel. For anyone who does get a printout or is able to see the computer screen, these four values for camber and caster will never ever be exactly as shown on this list. When we do have adjustments available, it is a very tedious process to nudge one close to where we want it, then it becomes even more tiring to tweak all four so as a group, they will give good tire wear with no pull. One car will end up with a little more camber on one wheel and a little more caster to offset it. Besides being within the tolerance range, we take what we get when those four numbers say the car will go straight.
Hopefully that gives you some more ideas, but the first things are to recheck the alignment, and switch the front tires side to side. Ask if they can give you a printout of the alignment too. I can interpret the numbers for you. Let me know how this turns out, then we'll figure out if we need to look further.
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Thursday, February 9th, 2023 AT 6:53 PM