Steering Shaft - Intermediate

This procedure replaces the intermediate steering shaft, which connects the steering column to the steering gear box, eliminating clunks or binding in the steering system.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupling bolt × 1 — M10 x 1.5, use new

Preparation

1. Park vehicle on level surface, place transmission in Park (automatic) or gear (manual), and apply parking brake
2. Turn ignition to OFF position and remove key
3. Chock rear wheels securely
4. Center the steering wheel and verify front wheels are pointing straight ahead
5. Install steering wheel holder or use locking device to prevent steering wheel rotation during procedure
6. Raise front of vehicle and support securely on jack stands at frame rails
7. Allow steering components to cool if vehicle was recently driven

Procedure

1. 1

   Access intermediate shaft upper connection
   Working from inside the cab, locate the lower steering column dust boot and cover at the firewall. Remove the cover screws and pull back the dust boot to expose the upper coupling connection of the intermediate shaft to the steering column.
   Torque spec

   Cover Screws14 Nm (10 lb-ft)
2. 2

   Mark upper shaft alignment
   Using a white paint pen or marker, make alignment marks across the upper coupling where the intermediate shaft connects to the steering column shaft. Mark both the shaft and coupling in a way that clearly shows their original rotational alignment. Take a photo for reference if possible.
   ℹ️These alignment marks are critical for maintaining proper steering alignment during reassembly.
3. 3

   Disconnect upper coupling
   Remove the upper coupling bolt that secures the intermediate shaft to the steering column shaft. Use a wrench to hold the coupling nut while loosening the bolt. Once removed, carefully slide the coupling upward off the steering column shaft splines. Do not allow the shafts to separate completely yet.
   Torque spec

   Coupling Bolt42 Nm (31 lb-ft)
4. 4

   Access lower shaft connection
   Move under the vehicle and locate the lower end of the intermediate shaft where it connects to the steering gear input shaft at the steering gear box. Clean any dirt or debris from the coupling area with a wire brush. Apply penetrating oil to the coupling bolt threads if corrosion is present.
   ⚠Ensure vehicle is securely supported before working underneath.
5. 5

   Mark lower shaft alignment
   Using a white paint pen or marker, make clear alignment marks across the lower coupling where the intermediate shaft connects to the steering gear input shaft. Mark both the shaft and coupling to indicate original rotational position. These marks must align during reassembly.
   ℹ️Misalignment at this connection can cause steering wheel off-center condition or binding.
6. 6

   Disconnect lower coupling
   Remove the lower coupling bolt that secures the intermediate shaft to the steering gear input shaft. Use a wrench to hold the coupling nut while removing the bolt. Once removed, carefully slide the coupling off the steering gear input shaft splines.
   Torque spec

   Coupling Bolt42 Nm (31 lb-ft)
7. 7

   Remove intermediate shaft assembly
   With both couplings disconnected, carefully remove the intermediate shaft assembly from the vehicle by guiding it downward and out from under the vehicle. Avoid hitting brake lines, wiring harnesses, or other components during removal. Inspect the old shaft for wear, binding, or damaged U-joints.
   ℹ️If shaft binds or clunks when rotated by hand, replacement is necessary.
8. 8

   Prepare new intermediate shaft
   Remove the new intermediate shaft from packaging and inspect for shipping damage. Verify that both upper and lower couplings move smoothly without binding. Check that splines are clean and free of debris. Do not apply grease to splines unless specified by manufacturer, as most come pre-lubricated.
   ℹ️Some replacement shafts come with new coupling bolts. Use new bolts if provided.
9. 9

   Install lower coupling connection
   Position the new intermediate shaft assembly and guide the lower coupling onto the steering gear input shaft splines. Align the coupling so that the bolt hole is accessible and positioned correctly. Ensure the shaft slides fully onto the splines. Align your reference marks to match the original position as closely as possible.
   ⚠Do not force the coupling onto splines. If resistance is felt, remove and inspect for debris or damage.
10. 10

    Secure lower coupling
    Install the new coupling bolt through the lower coupling and steering gear input shaft. Start the bolt by hand to ensure proper thread engagement. Tighten the coupling bolt to specification using a torque wrench. Verify the coupling cannot rotate on the shaft after tightening.
    Torque spec

    Coupling Bolt42 Nm (31 lb-ft)
11. 11

    Install upper coupling connection
    From inside the vehicle, guide the upper coupling onto the steering column shaft splines. Align the coupling with your original alignment marks to ensure proper rotational position. The coupling should slide onto the splines smoothly. Ensure it is fully seated on the splines before installing the bolt.
    ⚠Verify steering wheel holder is still in place and wheel has not rotated.
12. 12

    Secure upper coupling
    Install the new coupling bolt through the upper coupling and steering column shaft. Start the bolt by hand to confirm proper thread engagement. Tighten the coupling bolt to specification using a torque wrench. Double-check that alignment marks are properly aligned after tightening.
    Torque spec

    Coupling Bolt42 Nm (31 lb-ft)
13. 13

    Reinstall dust boot and cover
    Position the dust boot back over the upper coupling area at the firewall. Install the cover over the dust boot and secure with the cover screws. Tighten screws to specification in a cross-pattern to ensure even seating.
    Torque spec

    Cover Screws14 Nm (10 lb-ft)
14. 14

    Remove steering wheel lock and lower vehicle
    Remove the steering wheel holder or locking device. Lower the vehicle from jack stands to the ground. Remove jack stands and chocks. The vehicle is now ready for verification testing.

Reassembly

1. Ensure both coupling bolts are torqued to specification and that alignment marks match original positions
2. Verify dust boot and cover are properly sealed to prevent dirt and moisture entry
3. Confirm steering wheel is centered with front wheels pointing straight ahead

Verification

• Start engine and turn steering wheel slowly from lock to lock while stationary, listening for clunks, binding, or unusual noises
• Verify steering wheel returns to center position smoothly when released
• With engine running, check for smooth power steering operation without binding or tight spots
• Test drive vehicle at low speed in a safe area and verify steering responds smoothly without play or clunking
• Verify steering wheel is centered when driving straight and no pulling occurs
• Recheck all coupling bolt torques after test drive
• Schedule a professional wheel alignment if steering wheel is off-center or vehicle pulls to one side

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