Steering Shaft - Intermediate

Replacement of the intermediate steering shaft connecting the steering column to the steering rack on a 1992 Dodge Viper, including disconnection of upper and lower shaft couplings.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Steering coupling bolt(s) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Center the steering wheel and verify front wheels are pointing straight ahead
4. Lock the steering wheel in the centered position using the ignition lock or a steering wheel locking device to prevent rotation during shaft removal
5. Raise the front of the vehicle with a floor jack and support securely on jack stands at the manufacturer-specified lift points
6. Ensure adequate working clearance beneath the vehicle

Procedure

1. 1

   Access the steering shaft from below
   Position yourself beneath the vehicle with adequate lighting. Locate the intermediate steering shaft running from the firewall area down to the steering rack. The shaft consists of upper and lower sections connected by a flexible coupling or U-joint, with pinch bolt couplings at each end.
2. 2

   Mark shaft alignment references
   Using a white paint marker, make precise alignment marks across the upper coupling (where the intermediate shaft connects to the column shaft at the firewall) and the lower coupling (where the intermediate shaft connects to the steering rack input shaft). Mark both the shaft and the coupling at each location. These marks are critical for maintaining proper steering alignment during reassembly.
3. 3

   Remove lower coupling bolt
   Locate the pinch bolt on the lower steering coupling where the intermediate shaft connects to the steering rack input shaft. Apply penetrating lubricant if the bolt shows corrosion. Remove the lower coupling bolt completely. You may need to spread the coupling slightly with a small pry bar to disengage it from the rack input shaft splines.
4. 4

   Remove upper coupling bolt
   Access the upper coupling area near the firewall where the intermediate shaft connects to the steering column shaft. Remove the upper coupling pinch bolt completely. Note the orientation of the coupling for reassembly.
5. 5

   Separate and remove intermediate shaft
   With both coupling bolts removed, carefully slide the intermediate shaft downward off the steering column shaft, then maneuver it to separate from the rack input shaft. The shaft may need to be rotated slightly to clear obstructions. Remove the complete intermediate shaft assembly from the vehicle. Inspect the U-joint or flex coupling in the center of the shaft for wear, binding, or damage.
6. 6

   Inspect coupling and shaft interfaces
   Examine the splines on both the steering column shaft (upper) and the steering rack input shaft (lower) for wear, damage, or debris. Clean any corrosion or dirt from the splines using a wire brush. Inspect the coupling clamps for cracks or deformation. Replace any damaged components.
7. 7

   Install new intermediate shaft
   Position the new or replacement intermediate shaft assembly. First, align the upper end with the steering column shaft, matching your alignment marks. Slide the upper coupling onto the column shaft splines, ensuring the pinch bolt hole in the coupling aligns properly. Next, align the lower end with the steering rack input shaft and slide the lower coupling onto the rack shaft splines, again referencing your alignment marks. Verify that both couplings are fully seated on their respective shafts.
8. 8

   Install and torque upper coupling bolt
   Install the upper coupling pinch bolt, ensuring it engages the flat or groove on the steering column shaft. Hand-tighten the bolt first, then torque to specification using a calibrated torque wrench. Verify the alignment marks are still matched after torquing.
   Torque spec

   Coupling Bolt28 Nm (21 lb-ft)
9. 9

   Install and torque lower coupling bolt
   Install the lower coupling pinch bolt, ensuring it engages the flat or groove on the steering rack input shaft. Hand-tighten the bolt first, then torque to specification using a calibrated torque wrench. Verify the alignment marks remain matched and that the coupling is not binding on the shaft.
   Torque spec

   Coupling Bolt28 Nm (21 lb-ft)
10. 10

    Verify shaft installation and remove steering lock
    Check that all coupling bolts are properly torqued and that the intermediate shaft shows no signs of binding or misalignment. Remove the steering wheel locking device. From inside the vehicle, slowly rotate the steering wheel lock-to-lock while observing the intermediate shaft from below to ensure smooth rotation without binding, clicking, or excessive play.

Reassembly

1. Lower the vehicle from jack stands using the floor jack
2. Remove jack stands and lower vehicle completely to the ground
3. Remove wheel chocks
4. Start the engine and verify power steering operation (if equipped)
5. Perform a slow-speed steering function test in a safe area to confirm proper operation before returning to normal driving

Verification

• Turn the steering wheel fully left and right with the engine running to verify no binding, clicking, or abnormal noise from the intermediate shaft area
• Verify the steering wheel is centered when the front wheels are pointing straight ahead
• Check that there is no excessive play or looseness in the steering system
• Perform a slow test drive and verify smooth steering input response with no vibration or unusual feedback through the steering wheel
• Visually inspect coupling bolts from beneath the vehicle to confirm they remain tight and properly seated

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