This procedure replaces the upper steering shaft on a 2011-2014 Ford F-150 with the 3.5L EcoBoost engine, addressing common issues like clunking or binding in the steering column.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Intermediate shaft bolt (if not included with shaft) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Ensure front wheels are pointed straight ahead and note steering wheel position
3. Chock rear wheels to prevent vehicle movement
4. Allow engine to cool completely if recently driven

Procedure

1. 1

   Access the steering column
   Remove the lower steering column cover by removing the screws (typically 2-3 screws). Pull the cover down and away from the column. Remove the upper steering column cover in the same manner, noting the location of all mounting points.
   Torque spec

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

   Mark shaft alignment
   Using a white paint marker or masking tape, mark the alignment between the upper steering shaft and the intermediate shaft at the lower coupling. This ensures proper reassembly alignment. Also mark the relationship between the upper shaft and the steering column.
   ℹ️Accurate alignment marking is critical for maintaining proper steering wheel position after reassembly.
3. 3

   Remove lower coupling bolt
   Locate the pinch bolt at the lower end of the upper steering shaft where it connects to the intermediate shaft. Using a combination wrench and socket, loosen and remove the pinch bolt. This bolt may have a lock nut; if so, remove the nut first. Note the orientation of the bolt for reinstallation.
   ⚠Support the intermediate shaft to prevent it from dropping when disconnected.
4. 4

   Disconnect lower coupling
   Carefully separate the upper steering shaft from the intermediate shaft by pulling the shafts apart. You may need to use a flat-head screwdriver to gently pry open the coupling. Do not force; if binding occurs, verify the pinch bolt is completely removed.
   ⚠Do not allow the intermediate shaft to rotate or turn the steering wheel from this point forward.
5. 5

   Remove upper mounting fasteners
   Locate the mounting bolts that secure the upper steering shaft assembly to the steering column housing (typically 2-3 bolts). Remove these bolts using the appropriate socket. On some models, these may be accessed from inside the cabin above the pedal assembly.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove upper steering shaft
   Carefully slide the upper steering shaft assembly upward and out of the steering column. You may need to tilt or angle the shaft to clear the column housing and dashboard structure. Take note of any bushings, seals, or spacers that may remain in the column for reinstallation.
   ℹ️Inspect the removed shaft for wear patterns, particularly at the splines and bearing surfaces, to confirm the failure mode.
7. 7

   Prepare new upper shaft
   Inspect the new upper steering shaft assembly to ensure it matches the removed part. Transfer any reusable components from the old shaft if required (such as mounting brackets). Clean the steering column bore and intermediate shaft splines with a clean rag to remove any debris or old grease.
   ℹ️Some replacement shafts come with pre-applied grease; do not remove this lubricant.
8. 8

   Install new upper shaft
   Insert the new upper steering shaft into the steering column from above, carefully aligning it with the column bore. Ensure any bushings or seals are properly positioned. Slide the shaft down until it reaches the intermediate shaft coupling position. Align the shaft according to the alignment marks made during disassembly.
   ⚠Verify the steering wheel position remains straight ahead before proceeding.
9. 9

   Secure upper mounting
   Install the upper mounting bolts through the steering shaft assembly into the column housing. Start all bolts by hand to ensure proper threading. Torque the mounting bolts to specification using a torque wrench in a cross-pattern if multiple bolts are present.
   Torque spec

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

    Connect lower coupling
    Align the lower end of the upper steering shaft with the intermediate shaft, matching the alignment marks made during disassembly. Ensure the coupling is fully engaged with the splines properly meshed. The shafts should slide together with minimal resistance.
    ⚠Misalignment at this connection can cause steering binding or premature wear.
11. 11

    Install coupling bolt
    Insert the pinch bolt through the lower coupling, ensuring it passes through both the coupling and the flat section of the shaft splines. Install the lock nut if equipped. Torque the bolt to the manufacturer's specification for intermediate shaft connections (typically 30-50 Nm, though not listed in provided specs - follow service manual).
    ⚠️The coupling bolt must be fully tightened to specification. An improperly secured coupling can separate during operation, causing complete loss of steering control.
12. 12

    Verify operation
    Before reinstalling covers, turn the steering wheel slowly from lock to lock while observing the shaft connections. Verify smooth operation with no binding, clicking, or unusual resistance. Check that all connections remain secure throughout the full range of motion.
    ℹ️Any binding or noise at this stage indicates improper installation and must be corrected before proceeding.
13. 13

    Reinstall steering column covers
    Position the upper steering column cover over the column and secure with the original screws. Install the lower cover in the same manner. Ensure all cover tabs are properly engaged and no gaps exist between covers and the dashboard.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

Reassembly

1. Verify all fasteners are tightened to specification
2. Confirm steering wheel position is centered with wheels straight ahead
3. Check that all steering column covers are securely fastened with no rattles

Verification

• Start the vehicle and verify no warning lights are illuminated on the instrument cluster
• Turn the steering wheel slowly from lock to lock while stationary, listening for any unusual noises or feeling for binding
• Perform a test drive at low speed in a safe area, verifying smooth steering operation and proper wheel centering
• Check for any clunking or popping noises when turning the wheel, especially during low-speed maneuvers
• Verify the steering wheel returns to center properly after turns

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