Steering Coupler

Remove and replace the intermediate steering shaft coupler that connects the steering column to the steering gear on the 2023 Chevrolet Bolt EUV.

Warnings

Tools required

Parts

• Steering shaft coupler assembly × 1 — Use OEM specification
• Coupler bolt (if not included with coupler) × 1 — GM 23499893 or equivalent

Preparation

1. Park vehicle on level ground and apply parking brake
2. Turn ignition off and remove key or key fob from vehicle
3. Disconnect negative battery cable and wait at least 2 minutes
4. Center the steering wheel and front wheels in the straight-ahead position
5. If available, install steering wheel holding tool to prevent rotation during service
6. Raise front of vehicle with floor jack and support on jack stands at manufacturer-specified points
7. Remove driver's side front wheel for better access to steering coupler area

Procedure

1. 1

   Access the steering coupler
   From underneath the vehicle, locate the intermediate steering shaft coupler where it connects the steering column to the steering gear input shaft. It is positioned near the firewall on the driver's side. Remove any underbody panels or covers if necessary to access the coupler. Clean the area around the coupler to prevent dirt from entering the steering system.
2. 2

   Mark coupler alignment
   Before disconnecting anything, use a white paint marker to mark the relationship between the upper steering shaft, the coupler, and the lower steering gear input shaft. Make alignment marks on all three components in the same rotational position. This ensures proper reassembly alignment and prevents clockspring damage.
3. 3

   Remove the coupler bolt
   Locate the coupler pinch bolt that secures the coupler to the steering gear input shaft. This is typically a 13mm or 15mm bolt. If the bolt is seized, apply penetrating oil and allow it to soak for several minutes. Using a socket and ratchet, loosen and remove the coupler bolt completely. The coupler may be a split-collar design with a pinch bolt.
4. 4

   Separate the coupler from steering gear
   With the bolt removed, the coupler should slide off the steering gear input shaft splines. If the coupler is tight, carefully use a flat blade screwdriver or small pry bar to spread the pinch clamp slightly. Do not force or damage the splines. Pull the coupler upward off the steering gear input shaft.
   ⚠Do not damage the steering gear input shaft splines or seals. If excessive force is required, verify the bolt is completely removed.
5. 5

   Remove upper coupler connection
   If the coupler has a second pinch bolt connecting it to the upper steering column shaft, mark its position and remove this bolt as well. Separate the coupler from the upper shaft. The entire coupler assembly should now be free. Inspect the steering shaft splines on both upper and lower shafts for damage or wear.
6. 6

   Inspect components
   Inspect the removed coupler for worn splines, cracks, excessive play, or rubber deterioration if it contains a dampening element. Inspect both steering shaft splines (upper column and lower gear input) for damage, rust, or wear. Clean the splines with a wire brush if necessary. Verify the new coupler matches the old one exactly.
7. 7

   Install new coupler
   Position the new coupler onto the upper steering column shaft first, aligning the splines and matching your alignment marks. Ensure the coupler is fully seated on the splines. Do not tighten the bolt yet. Then align the lower portion of the coupler with the steering gear input shaft, matching your alignment marks, and slide it onto the splines until fully seated.
   ⚠Verify alignment marks match and steering wheel has not rotated from center position before proceeding.
8. 8

   Install and torque coupler bolt
   Install the new coupler pinch bolt (or reuse if specified by manufacturer and in good condition). Hand-thread the bolt first to ensure proper engagement. Using a torque wrench, tighten the coupler bolt to specification. If there are two bolts (upper and lower connections), torque both to specification. Verify the coupler does not rotate on either shaft after torquing.
   ⚠Use only a torque wrench for final tightening. Over-torquing can damage the steering gear input shaft.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
9. 9

   Verify installation
   Check that all alignment marks still match after torquing. Verify there is no binding or unusual resistance by carefully rotating the steering gear input shaft slightly by hand (only if steering wheel is secured). Confirm the coupler is fully seated on both shafts with no gaps.
10. 10

    Reinstall components and wheel
    Reinstall any underbody covers or panels that were removed. Install the driver's side front wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle to the ground. Torque the wheel lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
11. 11

    Reconnect battery and test
    Reconnect the negative battery cable. Start the vehicle and verify the power steering system operates normally without warning lights. Turn the steering wheel slowly lock-to-lock while stationary to verify no binding, clicking, or abnormal noises from the coupler area. Test drive the vehicle at low speed in a safe area to confirm proper steering operation.

Reassembly

1. Ensure all alignment marks match before final torquing
2. Verify steering wheel remained centered throughout the procedure
3. Do not skip the verification step of checking for proper steering operation before returning vehicle to service

Verification

• Start vehicle and verify no power steering warning lights are illuminated
• Turn steering wheel slowly from lock to lock while stationary - should be smooth with no binding, clicking, or clunking
• Test drive vehicle and verify steering response is normal with no unusual noises or vibrations
• Verify steering wheel is still centered when driving straight
• Check that all steering wheel controls and horn function properly (confirms clockspring is not damaged)

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