Replace the intermediate steering shaft that connects the steering column to the steering rack, eliminating steering clunks and play.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM Ford specification

Preparation

1. Park vehicle on level surface with front wheels pointed straight ahead
2. Set parking brake and place wheel chocks behind rear tires
3. Turn ignition to OFF and remove key
4. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
5. Lock the steering wheel in the straight-ahead position using a steering wheel holder or seatbelt through the wheel
6. Raise front of vehicle and support securely on jack stands at the frame rails

Procedure

1. 1

   Access the intermediate steering shaft
   Working from underneath the vehicle, locate the intermediate steering shaft between the steering column and the steering rack. Remove the lower steering shaft cover panel if equipped by removing the retaining screws. Clean the area around both U-joint connections with wire brush and apply penetrating oil to pinch bolt threads.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
2. 2

   Mark shaft alignment
   Using a white paint marker, make alignment marks across both U-joint connections: one mark across the upper shaft-to-column connection and one mark across the lower shaft-to-rack connection. These marks are critical for proper reassembly alignment and preventing steering wheel misalignment.
   ⚠Proper alignment marking is essential. Misalignment during installation will result in off-center steering wheel.
3. 3

   Disconnect upper shaft connection
   Locate the upper pinch bolt at the steering column U-joint connection. Using a 15mm socket, loosen and remove the upper pinch bolt completely. Spread the pinch bolt clamp slightly using a flat-head screwdriver if needed to release tension on the shaft splines.
   ℹ️The pinch bolt may be difficult to access. A universal joint socket extension may be helpful.
4. 4

   Disconnect lower shaft connection
   Locate the lower pinch bolt at the steering rack input shaft U-joint connection. Using a 13mm socket, loosen and remove the lower pinch bolt completely. Spread the pinch bolt clamp slightly if needed to free the connection.
   ⚠️Verify the steering wheel remains locked and has not rotated. Any rotation can damage the clockspring.
5. 5

   Remove intermediate steering shaft
   Carefully collapse or separate the intermediate shaft from both the upper steering column shaft and lower steering rack input shaft. You may need to gently pry the U-joint clamps open slightly. Remove the intermediate shaft assembly from the vehicle, noting its orientation for installation.
   ⚠Support the shaft during removal to prevent it from falling and causing injury or damage.
6. 6

   Inspect and prepare new shaft
   Inspect the steering column and rack input shaft splines for wear, damage, or corrosion. Clean both shafts with a wire brush if needed. Compare the new intermediate shaft with the old one to verify correct replacement part. Check that the new shaft collapses and extends smoothly.
   ℹ️Do not apply grease to the splines unless specifically called for by the new shaft manufacturer.
7. 7

   Install new intermediate shaft
   Position the new intermediate shaft assembly, aligning it with both the upper steering column shaft and lower steering rack input shaft. Ensure the shaft orientation matches the original installation. Slide the U-joints onto the splines at both ends, aligning your paint marks from disassembly. The shaft should slide on with moderate effort.
   ⚠Verify alignment marks match before proceeding. The steering wheel must remain in the locked, straight-ahead position.
8. 8

   Install upper pinch bolt
   Insert the upper pinch bolt through the steering column U-joint clamp. Ensure the clamp gap is positioned correctly and the bolt passes through both sides of the clamp. Thread the bolt by hand first, then tighten to 31 Nm (23 lb-ft) using a torque wrench. Verify the shaft cannot be pulled apart after tightening.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Install lower pinch bolt
   Insert the lower pinch bolt through the steering rack U-joint clamp. Ensure proper clamp alignment and that the bolt passes through both sides of the clamp. Thread by hand, then tighten to 31 Nm (23 lb-ft) using a torque wrench. Verify the connection is secure and cannot be separated.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Reinstall cover and lower vehicle
    If equipped, reinstall the lower steering shaft cover panel and secure with retaining screws, torquing to 12 Nm (9 lb-ft). Remove the steering wheel locking device. Lower the vehicle from jack stands to the ground.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

Reassembly

1. Reconnect the negative battery cable
2. Ensure all pinch bolts are torqued to specification and properly seated
3. Verify no tools or parts were left in the work area

Verification

• Start the engine and verify no warning lights related to steering or airbag systems
• Turn the steering wheel slowly from lock to lock while stationary, listening for any binding, clicking, or unusual noises
• Verify the steering wheel is centered when the front wheels are pointed straight ahead
• Test drive the vehicle at low speed, checking for proper steering response and no clunking during turns or over bumps
• Verify no play or looseness in the steering wheel
• Re-check all pinch bolt torque values after test drive

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