This procedure covers the removal and replacement of the steering coupler (intermediate shaft) connecting the steering column to the steering gear on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Steering coupler/intermediate shaft assembly × 1 — Use OEM specification

Preparation

1. Park the vehicle on a level surface and apply the parking brake
2. Place wheel chocks behind the rear wheels
3. Turn the steering wheel to the center position and lock the steering column (do not turn after this point)
4. Disconnect the negative battery terminal and wait 2 minutes for airbag system capacitors to discharge
5. Raise the front of the vehicle and support securely on jack stands
6. Remove any underbody panels or skid plates that obstruct access to the steering coupler area

Procedure

1. 1

   Access the steering coupler
   From underneath the vehicle, locate the steering coupler (intermediate shaft) that connects the steering column shaft to the steering gear input shaft. You may need to remove the lower steering column cover from inside the cab for better access to the upper connection point.
2. 2

   Mark alignment positions
   Using a paint pen or marker, make alignment marks on the coupler and both shafts (steering column shaft and steering gear input shaft) to ensure proper orientation during reassembly. Mark the coupling bolt position relative to the shaft flats or splines.
   ⚠Accurate alignment marks are critical to prevent steering wheel misalignment and ensure proper steering operation.
3. 3

   Remove upper coupling bolt
   Locate the upper coupling bolt that connects the steering coupler to the steering column shaft. Using the appropriate socket, remove this bolt completely. You may need to work from inside the cab depending on access.
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
4. 4

   Remove lower coupling bolt
   From underneath the vehicle, locate and remove the lower coupling bolt that connects the steering coupler to the steering gear input shaft. Support the coupler with one hand as you remove the bolt to prevent it from dropping.
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
5. 5

   Remove steering coupler
   Carefully slide the steering coupler off both shaft ends. You may need to gently pry or wiggle the coupler to separate it from the splined connections. Work it free from the upper steering column shaft first, then carefully maneuver it away from the lower steering gear shaft.
6. 6

   Inspect components
   Inspect the splines on both the steering column shaft and steering gear input shaft for wear, damage, or corrosion. Check the coupler for excessive play, damaged bearings, worn splines, or torn boots. Replace any damaged components.
   ℹ️Common failure points include worn splines causing play and torn dust boots allowing contamination.
7. 7

   Install new steering coupler
   Position the new or replacement steering coupler and carefully align it with both shafts using your alignment marks as reference. Slide the coupler onto the steering column shaft first, ensuring the splines engage properly, then align and engage the lower end onto the steering gear input shaft. Verify that the alignment marks line up correctly.
   ⚠Ensure proper spline engagement on both ends before installing bolts. The coupler should slide on smoothly without excessive force.
8. 8

   Install and torque upper coupling bolt
   Insert the upper coupling bolt through the coupler and steering column shaft, ensuring it passes through the proper alignment holes or pinch bolt location. Torque the bolt to specification using a torque wrench.
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
9. 9

   Install and torque lower coupling bolt
   Insert the lower coupling bolt through the coupler and steering gear input shaft. Verify proper alignment with your reference marks, then torque the bolt to specification using a torque wrench.
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
10. 10

    Reinstall covers and lower vehicle
    Reinstall any steering column covers removed for access. Reinstall any underbody panels or skid plates. Carefully lower the vehicle from the jack stands.

Reassembly

1. Reconnect the negative battery terminal
2. Verify the steering wheel is centered when the front wheels are pointing straight ahead
3. If steering wheel position is off-center, the coupler may have been installed incorrectly and must be repositioned

Verification

• Start the engine and verify the power steering system operates normally with no unusual noises
• Turn the steering wheel lock-to-lock while stationary and verify smooth operation with no binding or clicking
• Test drive the vehicle at low speed and verify proper steering response and no play in the steering wheel
• Verify the steering wheel returns to center properly after turns
• Inspect the coupler area for any unusual noises or movement while an assistant turns the steering wheel

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