Remove and replace the intermediate steering shaft connecting the steering column to the steering gearbox on a 1966 Chevrolet Corvette with 327ci V8 engine.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification or quality aftermarket
• Steering shaft coupler bolts × 2 — Use OEM specification
• Steering shaft U-joint × 1 — If worn or damaged

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Chock rear wheels securely
3. Center the steering wheel and front wheels in straight-ahead position
4. Disconnect negative battery cable if equipped with optional power steering to prevent accidental starter engagement
5. Raise front of vehicle with floor jack and support securely on jack stands under frame rails
6. Allow steering components to cool if vehicle was recently driven

Procedure

1. 1

   Access the steering shaft from underneath
   Position yourself under the vehicle with adequate lighting. Locate the intermediate steering shaft which connects the steering column shaft exiting the firewall to the steering gearbox input shaft. On the 1966 Corvette, the steering column shaft runs from the base of the steering column through the firewall area down to the steering box mounted on the frame. Verify the actual configuration on your specific car, as the connection between the column and steering gear may be via a flexible coupling rather than a separate intermediate shaft with universal joints. Inspect the shaft and universal joints for wear, looseness, or damage.
2. 2

   Mark shaft alignment positions
   Using a center punch or paint marker, make alignment marks on the intermediate shaft where it connects to both the steering column shaft coupler and the steering gearbox input shaft coupler. Mark both the shaft and the coupler at each connection point to ensure proper phasing during reassembly. These marks are critical - misalignment will cause binding and potential steering failure.
3. 3

   Remove lower steering shaft coupler bolts
   Locate the coupler connecting the intermediate shaft to the steering gearbox input shaft. Remove the 2 pinch bolts securing this connection. Verify the head size before purchasing tools, as the exact bolt head size for this connection is not confirmed for this vehicle. Apply penetrating oil if bolts are corroded. Support the intermediate shaft while removing the bolts to prevent it from dropping.
4. 4

   Separate lower shaft connection
   Carefully spread the coupler clamp slightly with a flat blade screwdriver if needed and slide the intermediate shaft off the steering gearbox input shaft splines. The shaft should slide off once the pinch bolts are removed. If stuck, tap gently with a rubber mallet while pulling - do not force or pry aggressively as this can damage splines.
5. 5

   Access upper steering shaft connection
   Move to the interior of the vehicle. You may need to remove the lower dash panel or work around it to access the upper connection point where the intermediate shaft connects to the steering column shaft below the dashboard. On some 1966 Corvettes, adequate access can be gained by working from underneath through the firewall area.
6. 6

   Remove upper steering shaft coupler bolts
   Locate the upper coupler connecting the intermediate shaft to the steering column shaft. Remove the 2 pinch bolts securing this connection. Support the intermediate shaft to prevent it from falling as you remove the fasteners.
7. 7

   Remove intermediate steering shaft
   With both couplers disconnected, carefully maneuver the intermediate steering shaft assembly out of the vehicle. Note the shaft routing and any brackets or guides it passes through for correct reinstallation. Inspect the universal joints for wear, binding, or looseness. Inspect shaft splines for damage or excessive wear.
8. 8

   Inspect and prepare components
   Clean the steering column shaft and steering gearbox input shaft splines with a wire brush. Remove any rust, dirt, or old grease. Inspect both shaft ends for damage, wear, or distortion. Check that the splines are not stripped or rounded. If the intermediate shaft U-joints show any play, binding, or rough rotation, replace the entire shaft assembly or rebuild the U-joints as needed.
9. 9

   Prepare new or serviced shaft
   Apply a light coat of white lithium grease or multi-purpose grease to the splines on both ends of the intermediate shaft. Lubricate the U-joint with appropriate grease if it has grease fittings. Ensure all grease fittings are functional and not plugged.
10. 10

    Install intermediate shaft to steering column
    Guide the intermediate shaft into position, routing it correctly through any brackets or supports. Align the upper end with the steering column shaft, matching your alignment marks. Slide the coupler onto the column shaft splines, ensuring proper engagement. The marks should align exactly. Install the 2 upper pinch bolts finger-tight only at this stage.
11. 11

    Connect shaft to steering gearbox
    Align the lower end of the intermediate shaft with the steering gearbox input shaft, matching your alignment marks. Ensure the steering wheel and gearbox are still in the straight-ahead position. Slide the coupler onto the gearbox input shaft splines with marks aligned. The shaft should slide on smoothly without force. Install the 2 lower pinch bolts finger-tight.
12. 12

    Verify alignment and tighten connections
    Double-check that all alignment marks match at both connections. Verify the steering wheel is still centered and front wheels are pointed straight ahead. With everything properly aligned, tighten all 4 coupler pinch bolts securely. Work in a cross pattern at each connection. No verified torque specification is available for this vehicle. Consult the 1966 Corvette factory service manual for the exact coupler pinch bolt torque before final tightening; do not rely on a generic estimate for safety-critical steering fasteners.
13. 13

    Check for binding and proper operation
    With the vehicle still on jack stands and wheels off the ground, rotate the steering wheel slowly from lock to lock. Feel for any binding, roughness, or tight spots. The steering should rotate smoothly through the entire range of motion. If any binding is detected, recheck alignment marks and U-joint condition. The intermediate shaft should rotate freely without binding.

Reassembly

1. Reinstall any dash panels or trim pieces removed for access
2. Lower vehicle from jack stands and remove wheel chocks
3. Reconnect negative battery cable if disconnected
4. Check power steering fluid level if equipped and top off as needed with GM Power Steering Fluid

Verification

• Start the engine and verify steering operates smoothly with no unusual noises
• Turn steering wheel fully from lock to lock while stationary, listening for any clicking, binding, or noise from the intermediate shaft
• Test drive the vehicle at low speed in a safe area, verifying steering response is normal with no play, binding, or unusual feedback
• Verify steering wheel returns to center properly after turns
• After test drive, inspect all shaft connections for any movement or looseness
• Recheck that all pinch bolt connections are tight

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