This procedure covers removal and replacement of the upper steering shaft on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including disconnection from the steering column and intermediate shaft.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Steering shaft coupling bolt × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Turn steering wheel to center position and verify wheels are pointed straight ahead
3. Turn ignition to OFF position and remove key
4. Disconnect negative battery cable and wait minimum 3 minutes for airbag system capacitor discharge
5. Remove driver's side lower steering column cover using T30 Torx bit
6. Lock the steering wheel in place using a steering wheel lock or tape to prevent rotation

Procedure

1. 1

   Access the upper steering shaft
   Remove the lower steering column covers by removing the Torx screws. Carefully pull the covers away from the column to expose the upper steering shaft connection point. You may need to remove the driver's knee bolster for better access depending on configuration.
   Torque spec

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

   Mark shaft alignment
   Using a white paint marker, make alignment marks across the upper steering shaft and the intermediate shaft coupling at the joint below the steering column. Also mark the upper shaft position relative to the steering column bracket. These marks are critical for maintaining proper steering wheel alignment during reassembly.
   ⚠Failure to properly mark alignment will result in off-center steering wheel position after reassembly.
3. 3

   Disconnect electrical connectors
   Locate and disconnect any electrical connectors attached to or near the upper steering shaft assembly. This may include column lock module connectors or position sensors depending on vehicle configuration. Press the locking tabs and carefully pull connectors straight off.
   ℹ️Take photos of connector routing for reference during reassembly.
4. 4

   Remove intermediate shaft coupling bolt
   Locate the pinch bolt or coupling bolt connecting the upper steering shaft to the intermediate shaft below the column. Use a socket and ratchet to remove this bolt completely. Support the intermediate shaft to prevent it from dropping.
   ⚠Do not reuse the old coupling bolt. Always install a new bolt during reassembly.
5. 5

   Separate shaft coupling
   Using a flat-head screwdriver, carefully spread the pinch clamp at the coupling joint. Wiggle the upper shaft while pulling to separate it from the intermediate shaft splines. If stuck, apply penetrating oil and wait several minutes before attempting again. Do not use excessive force.
   ⚠Avoid damaging the splines during separation as this will affect steering feel and may cause binding.
6. 6

   Remove upper shaft mounting hardware
   Locate and remove the mounting bolts securing the upper steering shaft assembly to the steering column support bracket. These are typically located near the firewall penetration point. Support the shaft assembly as you remove the final fastener.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Remove upper steering shaft
   Carefully slide the upper steering shaft assembly downward and out of the steering column. Guide it through the column opening, being careful not to damage any surrounding trim or wiring. Inspect the removed shaft for wear, binding, or damage that necessitated replacement.
   ℹ️Inspect the column bearings and bushings for wear while the shaft is removed. Replace if excessive play is detected.
8. 8

   Install new upper steering shaft
   Insert the new upper steering shaft assembly into the steering column from below, guiding it carefully through the column opening. Align the shaft with the column support bracket mounting holes. Ensure any integrated electrical connectors or components are properly oriented per your reference photos.
   ⚠Verify the shaft slides smoothly without binding. Any resistance indicates misalignment that must be corrected before proceeding.
9. 9

   Install mounting bolts
   Install the mounting bolts securing the upper steering shaft assembly to the column support bracket. Tighten the bolts to specification using a torque wrench. Ensure the shaft is properly seated in all mounting points before final torquing.
   Torque spec

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

    Connect to intermediate shaft
    Align the upper steering shaft splines with the intermediate shaft splines using the alignment marks made during disassembly. Slide the upper shaft onto the intermediate shaft, ensuring full engagement of the splines. The alignment marks should line up perfectly.
    ⚠If alignment marks do not match, do not force the connection. Remove and verify steering wheel has not rotated and intermediate shaft is in correct position.
11. 11

    Install new coupling bolt
    Install the new intermediate shaft coupling bolt through the pinch clamp. Tighten to the specified torque value. Verify the pinch clamp fully engages both shaft sections and that there is no play in the connection.
    ⚠️Always use a new coupling bolt. Reusing the old bolt can result in shaft separation and complete loss of steering control.
12. 12

    Reconnect electrical components
    Reconnect all electrical connectors to the steering column components, ensuring each connector clicks fully into place. Route wiring according to your reference photos to avoid pinching or interference with steering shaft movement.
13. 13

    Verify shaft operation
    Before reinstalling covers, manually rotate the steering shaft through its full range of motion from lock to lock. Verify smooth operation with no binding, clicking, or unusual resistance. The shaft should return smoothly to center position.
    ⚠Any binding or abnormal resistance indicates a problem that must be resolved before completing reassembly.

Reassembly

1. Reinstall the lower steering column covers and secure with T30 Torx screws to specification
2. Reinstall driver's knee bolster if removed
3. Remove steering wheel lock or tape
4. Reconnect negative battery cable
5. Turn ignition to ON position without starting engine and verify no airbag warning lights remain illuminated after system check completes

Verification

• Start the engine and verify electric power steering system operates normally with no warning lights
• With engine running, turn steering wheel slowly from lock to lock and verify smooth operation with no binding, noise, or vibration
• Verify steering wheel is centered when wheels are pointed straight ahead
• Test drive vehicle at low speed in a safe area to confirm proper steering response and centering
• If steering wheel is off-center, the intermediate shaft or steering wheel may need adjustment per service manual procedures

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