Steering Shaft - Intermediate

This procedure covers the removal and replacement of the intermediate steering shaft on a 2023 Chevrolet Bolt EUV, connecting the steering column to the steering rack.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Coupling bolt (upper) × 1 — M10 x 1.5 x 35mm
• Coupling bolt (lower) × 1 — M10 x 1.5 x 35mm

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position (wheels straight ahead)
4. Turn ignition off and remove key fob from vehicle
5. Lock steering wheel in center position using steering wheel lock or have assistant hold firmly
6. Raise front of vehicle and support on jack stands
7. Remove driver side front wheel for access if needed

Procedure

1. 1

   Access intermediate shaft from underneath
   Position yourself under the vehicle at the driver side footwell area. Locate the intermediate steering shaft connecting the steering column to the steering rack. The shaft will have two U-joint style couplings - one at the column and one at the rack.
2. 2

   Mark shaft alignment positions
   Using a white paint marker or grease pencil, make alignment marks across both coupling joints (upper and lower). Mark the shaft position relative to the steering column and the steering rack pinion. These marks are critical for maintaining proper steering alignment during reinstallation.
3. 3

   Remove upper coupling bolt
   Apply penetrating oil to the upper coupling bolt threads if corrosion is present. Using the appropriate socket, remove the upper coupling bolt that connects the intermediate shaft to the steering column shaft. Support the intermediate shaft to prevent it from falling.
   ⚠Do not allow the steering column shaft to rotate or move during this process.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
4. 4

   Remove lower coupling bolt
   Locate the lower coupling bolt connecting the intermediate shaft to the steering rack pinion input shaft. Remove this bolt completely. The intermediate shaft should now be free from both connection points but may still be held by friction in the couplings.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
5. 5

   Separate and remove intermediate shaft
   Carefully separate the intermediate shaft from both the upper column shaft and lower rack pinion. The shaft may require gentle prying or twisting to break free from the splined connections. Once free, remove the intermediate shaft from the vehicle by maneuvering it out from the underside. Inspect the shaft for wear, damage, or excessive play in the U-joints.
6. 6

   Inspect connection points
   With the intermediate shaft removed, inspect the steering column shaft splines and steering rack pinion splines for damage, wear, or debris. Clean both connection points with a wire brush if needed. Verify the steering wheel has not moved from the centered position.
   ⚠If the steering wheel has moved, do not attempt to force it back. Consult a professional to avoid clockspring damage.
7. 7

   Position new intermediate shaft
   Position the new (or serviced) intermediate shaft into the vehicle from underneath. Align the upper coupling with the steering column shaft splines, ensuring proper orientation using your reference marks. The shaft should slide onto the splines with light pressure and align with the previously made marks.
8. 8

   Connect lower coupling to rack
   Align the lower coupling with the steering rack pinion shaft splines. Ensure the alignment marks line up correctly. The coupling should engage smoothly onto the pinion shaft. Verify both upper and lower couplings are fully seated on their respective shafts.
9. 9

   Install and torque lower coupling bolt
   Insert the new lower coupling bolt through the coupling and pinion shaft. Thread the bolt by hand to ensure proper engagement. Using a torque wrench, tighten the bolt to specification. Verify the coupling cannot rotate on the pinion shaft after torquing.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
10. 10

    Install and torque upper coupling bolt
    Insert the new upper coupling bolt through the coupling and steering column shaft. Thread by hand first, then torque to specification using a torque wrench. Ensure the coupling is properly seated and cannot rotate on the column shaft.
    Torque spec

    Coupling Bolt34 Nm (25 lb-ft)
11. 11

    Verify installation and clearances
    Check that all alignment marks are properly aligned. Verify the intermediate shaft has adequate clearance from surrounding components throughout its full range of motion. Confirm both coupling bolts are fully torqued and secure. Remove steering wheel lock if used.

Reassembly

1. Reinstall driver side front wheel if removed and torque lug nuts to specification
2. Lower vehicle from jack stands
3. Remove wheel chocks

Verification

• Start vehicle (ready mode) and verify no warning lights related to steering system
• With vehicle still parked, slowly turn steering wheel lock-to-lock and verify smooth operation with no binding, clicking, or unusual noises
• Verify steering wheel returns to center position when released
• Test drive vehicle in safe area at low speed, checking for proper steering response and centering
• Verify steering wheel is properly centered when driving straight
• Listen for any clunking or knocking noises when turning or going over bumps
• If steering wheel is off-center after installation, a professional wheel alignment may be required

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