Steering Shaft - Intermediate

This procedure replaces the intermediate steering shaft connecting the steering column to the steering rack on a 2009 Aston Martin DB9, restoring proper steering feel and eliminating clunks or binding.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Steering shaft U-joint pinch bolt(s) × 2 — Use OEM specification
• Steering shaft coupling fasteners × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake.
2. Turn ignition to OFF position and remove key from ignition.
3. Chock rear wheels securely.
4. Raise vehicle on lift or jack stands to provide access to underside. Ensure vehicle is stable and secure.
5. Center the steering wheel with wheels pointing straight ahead. Verify wheel is centered by checking equal spoke positions.
6. If equipped, disable steering lock by turning ignition to accessory position momentarily, then OFF.
7. Gather all tools and new parts before beginning disassembly.

Procedure

1. 1

   Access driver's footwell and lower steering column area
   Remove the driver's side lower dash panel or kick panel to expose the upper steering column and firewall penetration area. This typically involves removing Torx fasteners around the perimeter of the lower trim panel. Set panel and fasteners aside in organized manner for reinstallation. Note: Torx driver set (T20-T50) — note: confirm actual fastener head type (Torx vs. hex/Allen) against Aston Martin DB9 documentation, as DB9 steering hardware may use hex sockets
2. 2

   Mark upper steering shaft alignment
   Locate the upper universal joint connection between the steering column shaft and the intermediate shaft just below the dash. Using a paint marker, create alignment marks across the U-joint clamp and both shaft ends. Mark at least two reference points 180 degrees apart to ensure proper rotational alignment during reassembly. Take a photo if helpful for reference.
3. 3

   Remove upper U-joint pinch bolt
   Locate the pinch bolt securing the upper U-joint clamp to the steering column shaft. This will typically be a Torx fastener. Apply penetrating lubricant if needed. Remove the pinch bolt completely and retain for comparison with replacement hardware. Note that some designs use a bolt with a locking feature or deformed threads that should be replaced.
4. 4

   Access lower steering shaft connection at rack
   Move to the underside of the vehicle. Locate the lower end of the intermediate steering shaft where it connects to the steering rack input shaft. This is typically forward of the front subframe crossmember and may be partially obscured by heat shields or belly pans. Remove any heat shields or protective covers blocking access to the lower U-joint connection using appropriate Torx or E-Torx fasteners.
5. 5

   Mark lower steering shaft alignment
   Using the paint marker, create alignment marks across the lower U-joint clamp, intermediate shaft end, and steering rack input shaft. Mark the clamp bolt position as well. These marks are critical for maintaining steering wheel centering during reassembly.
6. 6

   Remove lower U-joint pinch bolt
   Remove the pinch bolt securing the lower U-joint to the steering rack input shaft. This fastener is typically a Torx bolt. Retain for comparison with replacement hardware. Note the orientation of the clamp opening for reassembly.
7. 7

   Separate and remove intermediate steering shaft
   With both pinch bolts removed, carefully separate the upper U-joint from the steering column shaft by gently prying or tapping the clamp open with a dead blow hammer. The shaft should slide off with moderate effort. Repeat for the lower connection at the rack input shaft. If joints are seized, apply additional penetrating lubricant and allow to soak, then use controlled pry bar pressure to open the clamp. Remove the complete intermediate shaft assembly from the vehicle through the cabin or underside depending on clearance.
8. 8

   Inspect steering column and rack input shafts
   With the intermediate shaft removed, inspect both the steering column output shaft and the rack input shaft for wear, corrosion, scoring, or damage. Check the splined or serrated areas where the U-joints clamp. Light surface rust is acceptable, but deep scoring or deformation requires addressing before installing the new shaft. Clean both shafts with wire brush if needed, but do not apply grease to clamping surfaces.
9. 9

   Prepare new intermediate steering shaft
   Unpack the new intermediate steering shaft and verify it matches the original in length, U-joint style, and end fittings. Check that replacement pinch bolts are included or available. Some shafts are collapsible for crash safety and must not be compressed or extended before installation. Handle carefully to avoid altering shaft length.
10. 10

    Install new shaft to steering rack
    Position the new intermediate shaft with the lower U-joint aligned to the steering rack input shaft. Align the clamp opening per your reference marks and slide the U-joint onto the rack shaft, matching your alignment marks as closely as possible. The splines or serrations should engage fully. Install the new lower pinch bolt finger-tight only at this stage.
11. 11

    Install new shaft to steering column
    From the cabin area, guide the upper end of the intermediate shaft to the steering column output shaft. Align the upper U-joint clamp with your reference marks and slide onto the column shaft. Ensure the steering wheel has not rotated from center position during this process. Install the new upper pinch bolt finger-tight.
12. 12

    Verify alignment and torque upper pinch bolt
    Verify all alignment marks are matched and the steering shaft assembly is properly seated at both ends with no binding or misalignment. Check that the U-joint clamps are fully engaged on the shafts. Torque the upper pinch bolt to the Aston Martin DB9 factory specification (verify exact value against official Aston Martin workshop documentation before final tightening; do not use the assumed 26 Nm / 19 lb-ft placeholder without confirmation). Do not rely on a generic estimate for this safety-critical steering fastener.y on a generic assumed value). Note: Torque the upper pinch bolt to the Aston Martin factory-specified value (verify exact figure in the DB9 workshop manual before tightening). Do not rely on a generic/assumed torque value for this safety-critical steering joint.
13. 13

    Torque lower pinch bolt
    Torque the lower pinch bolt at the steering rack connection to the Aston Martin DB9 factory specification (verify exact value against official Aston Martin workshop documentation before final tightening; do not use the assumed 26 Nm / 19 lb-ft placeholder without confirmation), ensuring the U-joint remains properly aligned during tightening. Verify the clamp has closed evenly around the shaft.ification (verify exact value against official service documentation before final tightening), ensuring the U-joint remains properly aligned during tightening. Note: Torque the lower pinch bolt at the steering rack connection to the Aston Martin factory-specified value (verify exact figure in the DB9 workshop manual before tightening), ensuring the U-joint remains properly aligned during tightening.
14. 14

    Check steering operation
    From the driver's seat, slowly rotate the steering wheel lock-to-lock while observing for any binding, unusual noise, or restriction. The wheel should turn smoothly through full range without interference. The steering wheel should return to center position with spokes level. If any binding is felt, recheck U-joint alignment and pinch bolt seating.
15. 15

    Reinstall protective covers and trim
    Reinstall any heat shields, belly pans, or protective covers removed for access to the lower steering connection. Torque fasteners to appropriate specification for trim components. Reinstall the driver's side lower dash panel or kick panel using original fasteners, ensuring all clips and fasteners are properly seated.

Reassembly

1. Torque all fasteners to specifications as noted in procedure steps.
2. Verify steering wheel remains centered after installation with wheels pointing straight ahead.
3. Ensure all trim panels and protective covers are reinstalled securely.
4. Lower vehicle from lift or jack stands and perform final steering operation check at ground level.

Verification

• Start engine and verify power steering operates normally with no unusual noises.
• Turn steering wheel lock-to-lock several times and verify smooth operation with no binding, clunking, or clicking.
• Verify steering wheel is centered when wheels are pointing straight ahead.
• Test drive vehicle at low speed in safe area, checking for proper steering response and no vibration or noise through steering wheel.
• After test drive, re-check all pinch bolt torque values to ensure nothing has loosened.

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