Steering Shaft - Intermediate

This procedure covers removal and replacement of the intermediate steering shaft connecting the steering column to the steering gearbox on a 1972 Ford F-100 with 302ci V8.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification or aftermarket equivalent
• Steering shaft U-joint bolt kit × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Chock rear wheels securely
3. Center steering wheel and verify front wheels are pointed straight ahead
4. Disconnect negative battery cable if removing steering column components
5. Raise front of vehicle and support securely on jack stands under frame rails
6. Allow steering components to cool if vehicle was recently driven

Procedure

1. 1

   Access intermediate steering shaft from underneath
   Position yourself under the vehicle with adequate lighting. Locate the intermediate steering shaft which connects the steering column shaft (upper) to the steering gearbox input shaft (lower). The steering connection on this vehicle typically uses a flexible coupling (rag joint) or single U-joint arrangement between the steering column shaft and the steering gearbox input shaft. Verify the exact configuration on your specific truck before proceeding, as clamping and fastener details vary. Clean the area around all connection points with wire brush and apply penetrating oil to all pinch bolts.
2. 2

   Mark steering shaft alignment
   Using paint marker or scribe, mark the alignment relationship between the intermediate shaft and the steering column shaft at the upper U-joint. Mark the alignment between the intermediate shaft and the steering gearbox input shaft at the lower U-joint. These marks are critical for proper reassembly and must align the flat surfaces on the shafts with the pinch bolt clamp surfaces. Verified detail (A 1972 F-100 has no clock spring (that is an airbag-era component, mid-1990s onward). This is an era-inappropriate component reference for a pre-1996 vehicle.): Do not turn the steering wheel with the intermediate shaft disconnected, as this can misalign the steering wheel relative to the front wheels and complicate reassembly.
3. 3

   Remove upper U-joint pinch bolt
   Locate the pinch bolt clamp at the upper U-joint where the intermediate shaft connects to the steering column shaft. Using appropriate wrench or socket, remove the pinch bolt and nut. The pinch bolt clamps the U-joint yoke around the splined or flattened section of the column shaft. Retain the pinch bolt hardware for inspection.
4. 4

   Remove lower U-joint pinch bolt
   Locate the pinch bolt clamp at the lower U-joint where the intermediate shaft connects to the steering gearbox input shaft. Remove the pinch bolt and nut using appropriate wrench or socket. This connection is typically under higher stress and may require more penetrating oil if corroded. Retain hardware for inspection.
5. 5

   Separate intermediate shaft from steering column
   With upper pinch bolt removed, carefully pry or tap the U-joint yoke to separate it from the steering column shaft. The yoke should slide off the splined or flattened section. If stuck due to corrosion, gently tap around the yoke clamp using a brass drift and hammer. Do not use excessive force that could damage the steering column shaft.
6. 6

   Separate intermediate shaft from gearbox input shaft
   With lower pinch bolt removed, carefully separate the lower U-joint yoke from the steering gearbox input shaft. This may require slight manipulation of the intermediate shaft angle while pulling downward. Once both ends are free, remove the intermediate shaft assembly from the vehicle by angling it out from under the dashboard area.
7. 7

   Inspect removed intermediate shaft
   Examine the removed intermediate shaft for wear, binding, or damage. Check both U-joints for excessive play by attempting to move the yokes perpendicular to their rotation axis. Inspect the clamping surfaces inside each yoke for wear grooves or cracks. Check that U-joint needle bearings rotate smoothly without binding or roughness. Replace shaft if any wear or damage is present.
8. 8

   Inspect pinch bolt hardware
   Examine all pinch bolts and nuts for thread damage, stretching, or corrosion. Pinch bolts should be replaced if threads are damaged or if bolts show signs of stretching at the clamp interface. These are critical safety fasteners and should not be reused if questionable.
9. 9

   Prepare steering shafts for installation
   Clean the splined or flattened sections of both the steering column shaft and gearbox input shaft using wire brush. Remove all rust, dirt, and old grease. Apply a thin coat of white lithium grease or equivalent to both shaft surfaces to prevent corrosion and aid future removal.
10. 10

    Position new or serviced intermediate shaft
    Angle the intermediate shaft assembly into position from underneath the vehicle. Verify that both U-joints move freely through their full range of motion before installation. Position the shaft so that both upper and lower yokes are accessible for installation onto their respective shafts.
11. 11

    Install intermediate shaft to steering column
    Align the upper U-joint yoke with the steering column shaft, ensuring the flat or splined surfaces match your alignment marks from disassembly. Slide the yoke fully onto the column shaft until it seats completely. The pinch bolt clamp gap should align with the flat surface on the shaft. Do not install pinch bolt yet.
12. 12

    Install intermediate shaft to gearbox input shaft
    Align the lower U-joint yoke with the steering gearbox input shaft, matching your alignment marks. Slide the yoke fully onto the input shaft until seated. Verify the pinch bolt clamp gap aligns with the flat surface on the gearbox shaft. With both ends positioned, verify steering wheel is still centered and front wheels are straight ahead.
13. 13

    Install and tighten upper pinch bolt
    Install the upper pinch bolt through the yoke clamp and thread on the nut. Tighten the pinch bolt firmly to secure the connection. The bolt should draw the clamp gap closed and compress around the steering column shaft. Torque specification not verified for this platform - obtain the factory torque value from the 1972 Ford F-100 shop manual before tightening this safety-critical steering fastener. Do not rely on a generic estimate.
14. 14

    Install and tighten lower pinch bolt
    Install the lower pinch bolt through the yoke clamp and thread on the nut. Tighten the pinch bolt firmly to secure the connection to the gearbox input shaft. Torque specification not verified for this platform - obtain the factory torque value from the 1972 Ford F-100 shop manual before tightening this safety-critical steering fastener. Do not rely on a generic estimate.
15. 15

    Verify steering operation
    From inside the cab, slowly rotate the steering wheel through its full range of motion from lock to lock while observing the intermediate shaft for binding, interference, or unusual movement. The shaft should rotate smoothly without any catching or binding throughout the entire steering range. Return steering wheel to center position.

Reassembly

1. Lower vehicle from jack stands
2. Reconnect negative battery cable if disconnected
3. Remove wheel chocks
4. Start engine and verify power steering operation if equipped
5. Road test vehicle at low speed in safe area to verify proper steering operation and centered steering wheel position

Verification

• Steering wheel should be centered with front wheels pointed straight ahead
• No binding or resistance should be felt when turning steering wheel through full range
• No unusual noises or clicking from intermediate shaft area during steering operation
• Vehicle should track straight with hands-off steering on level road
• Visually inspect both pinch bolts are fully tightened with no gap in clamp

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