Steering Shaft - Intermediate

Replace the intermediate steering shaft connecting the steering column to the steering gear box on a 1994-2007 Dodge Ram 2500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification or Dorman 425-316
• Coupling bolt hardware kit × 1 — Check if included with shaft or purchase separately

Preparation

1. Park vehicle on level surface with front wheels pointed straight ahead
2. Set parking brake and place wheel chocks behind rear wheels
3. Turn ignition to OFF position and remove key
4. Disconnect negative battery cable to prevent airbag deployment
5. Wait at least 2 minutes after battery disconnect before proceeding
6. Optional: Raise front of vehicle with jack and secure on jack stands for better access to lower coupling
7. Apply penetrating oil to upper and lower coupling bolts and allow to soak for 10-15 minutes

Procedure

1. 1

   Mark steering shaft alignment
   Using white paint marker or chalk, mark the relationship between the intermediate shaft and both the steering column shaft (upper) and steering gear input shaft (lower). Make clear alignment marks across both halves of each coupling to ensure proper reassembly. This is critical for maintaining steering wheel centering.
2. 2

   Access upper coupling
   From inside the cab, locate the upper coupling where the intermediate shaft connects to the steering column shaft just below the dash. You may need to remove the lower dash panel or knee bolster for better access depending on model year. The coupling is typically a pinch bolt style connection.
3. 3

   Remove upper coupling bolt
   Loosen and remove the upper coupling pinch bolt. Support the intermediate shaft to prevent it from dropping suddenly. If the bolt is seized, apply additional penetrating oil and allow to soak. Do not use excessive force that could damage the steering column shaft splines.
4. 4

   Access lower coupling
   Working from under the vehicle (either from below or through the wheel well), locate the lower coupling where the intermediate shaft connects to the steering gear input shaft. On 4WD models, you may need to work around the front differential and axle. Clean the area around the coupling with a wire brush to remove dirt and rust.
5. 5

   Remove lower coupling bolt
   Loosen and remove the lower coupling pinch bolt. This bolt is often severely rusted and may require heat or additional penetrating oil. Support the intermediate shaft to prevent sudden movement. Note the orientation of the coupling and any washers or spacers present.
   Torque spec

   Coupling Bolt34 Nm (25 lb-ft)
6. 6

   Separate upper coupling
   Carefully slide or pry the upper coupling off the steering column shaft. The coupling may be tight on the splines and require gentle rocking or prying with a flat head screwdriver. Do NOT turn the steering wheel once disconnected. If the coupling is severely stuck, tap gently with a rubber mallet while applying upward pressure.
7. 7

   Remove intermediate shaft
   Support the intermediate shaft and carefully maneuver it out of the vehicle. On 4WD models with the Cummins diesel, you will need to work around the front axle and steering linkage. The shaft may need to be rotated or angled to clear obstructions. Remove the shaft from the cabin area or from underneath depending on which provides easier access.
8. 8

   Inspect steering components
   Inspect the steering column shaft and steering gear input shaft for wear, damage, or rust. Clean both shaft splines with a wire brush. Check that the steering wheel is still centered and wheels are straight ahead. Inspect the steering gear dust boot for tears or damage. Replace any damaged components before proceeding.
9. 9

   Install new intermediate shaft
   Position the new intermediate shaft in the vehicle, aligning it with both the upper steering column shaft and lower steering gear input shaft. Ensure the shaft is oriented correctly by referencing your alignment marks and the collapsed length is appropriate for the vehicle. The shaft should slide onto both splined shafts without forcing.
10. 10

    Install lower coupling
    Slide the lower coupling onto the steering gear input shaft, aligning your reference marks to maintain proper steering geometry. Ensure the coupling is fully seated on the shaft splines. Install the lower coupling bolt finger-tight, ensuring it passes through the pinch slot and engages the shaft properly.
    Torque spec

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

    Install upper coupling
    Slide the upper coupling onto the steering column shaft, aligning your reference marks. Verify the coupling is fully seated on the splines. Install the upper coupling bolt finger-tight through the pinch slot. Double-check that both couplings are properly aligned before final tightening.
12. 12

    Torque coupling bolts
    Using a torque wrench, tighten the lower coupling pinch bolt to the manufacturer-specified value (typically approximately 21-36 ft-lbs / 28-49 Nm — verify against factory service manual for your year), then tighten the upper coupling bolt to the same specification. Verify both couplings are secure and there is no play in the intermediate shaft connection. Check that alignment marks still match after torquing.
    Torque spec

    Coupling Bolt34 Nm (25 lb-ft)
13. 13

    Verify steering operation
    Reconnect the negative battery cable. With the vehicle still raised or on the ground, note that steering effort will be high with the engine off due to lack of power assist. Slowly rotate the steering wheel through its range while checking for binding, unusual noises, or interference, then re-verify with the engine running. Verify the steering wheel returns to center smoothly. Check that the steering wheel is still centered when wheels are straight ahead.

Reassembly

1. Reinstall any dash panels or knee bolsters removed for access
2. Lower vehicle if raised on jack stands
3. Remove wheel chocks

Verification

• Start the engine and turn the steering wheel lock-to-lock while stationary, listening for any unusual noises or binding
• Verify steering wheel is centered when wheels are pointed straight ahead
• Test drive the vehicle at low speed in a safe area, checking for proper steering response and no unusual noises
• Verify no play or looseness in the steering system by rocking the steering wheel back and forth
• Check coupling bolts for proper torque after test drive
• Verify the airbag light is not illuminated on the instrument cluster after reconnecting battery

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