This procedure covers removal and installation of the intermediate steering shaft on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine, connecting the steering column to the steering rack.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Coupling bolt × 1 — M12 grade 10.9 bolt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and verify wheels are straight
4. Raise front of vehicle and support securely on jack stands at frame rails
5. Remove engine under-shield or splash guards for access to steering components

Procedure

1. 1

   Mark steering shaft alignment
   Before loosening any fasteners, use a marker or paint pen to make alignment marks across both the upper and lower joints of the intermediate shaft where it connects to the steering column and steering rack. Draw a line that spans both halves of each coupling to ensure proper clocking during reassembly. This is critical for maintaining proper steering geometry.
2. 2

   Access upper coupling at steering column
   Working from inside the cab, locate the upper coupling where the intermediate shaft connects to the steering column beneath the dashboard. You may need to remove the lower dash cover panel for better access. Ensure the steering wheel remains centered and do not rotate it during this procedure.
3. 3

   Remove upper coupling bolt
   Using a 13mm socket, remove the upper coupling bolt that secures the intermediate shaft to the steering column shaft. The bolt may have a pinch-style clamp. Apply penetrating oil if the bolt is difficult to access or corroded. Keep the bolt for reference if installing a new shaft.
   ⚠Do not allow the shaft to rotate or drop when removing the bolt, as this can damage splines
   Torque spec

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

   Separate upper coupling
   Carefully spread the pinch clamp using a pry bar or flat screwdriver while pulling the intermediate shaft downward to separate it from the steering column shaft. The splined connection should slide apart. If stuck, apply gentle rocking motion while pulling - do not use excessive force.
5. 5

   Access lower coupling at steering rack
   Move to underneath the vehicle. Locate the lower coupling where the intermediate shaft connects to the steering rack input shaft. Clean any dirt or debris from around the coupling area with a wire brush.
6. 6

   Remove lower coupling bolt
   Using a 13mm socket, remove the lower coupling bolt that secures the intermediate shaft to the steering rack input shaft. Verify your alignment marks are visible before separation. This bolt also uses a pinch-style clamp design.
   ℹ️Support the intermediate shaft to prevent it from falling when the lower bolt is removed
   Torque spec

   Coupling Bolt39 Nm (29 lb-ft)
7. 7

   Separate lower coupling and remove shaft
   Spread the lower pinch clamp and slide the intermediate shaft off the steering rack input shaft splines. Maneuver the shaft assembly out from between the firewall and steering rack. Note the routing path and any clips or guides that position the shaft, as these must be reinstalled correctly.
8. 8

   Inspect components
   Examine the removed shaft for wear, damage, or excessive play at the U-joint or coupling points. Check the splines on both the steering column and rack input shafts for damage or excessive wear. Clean the splines with a wire brush and inspect the rubber dust boots for tears. Replace any damaged components.
9. 9

   Prepare new or replacement shaft
   If installing a new shaft, ensure it matches the length and configuration of the original. Apply a thin coat of white lithium grease to the splines on both ends of the intermediate shaft and to the mating splines on the steering column and rack input shafts. Do not over-grease.
10. 10

    Install shaft to steering rack
    Position the intermediate shaft and slide the lower end onto the steering rack input shaft splines. Align your reference marks made during disassembly. The shaft should slide on smoothly with the splines properly indexed. Ensure any routing clips or guides are engaged.
11. 11

    Install lower coupling bolt
    Install the lower coupling bolt through the pinch clamp and thread into place. Ensure the clamp gap is properly positioned around the bolt. Torque the bolt to specification using a calibrated torque wrench. Verify alignment marks are still matched after tightening.
    Torque spec

    Coupling Bolt39 Nm (29 lb-ft)
12. 12

    Connect upper coupling to steering column
    From inside the vehicle, slide the upper end of the intermediate shaft onto the steering column shaft splines. Align your reference marks carefully. The shaft must be fully seated on the splines with no gap at the coupling.
13. 13

    Install upper coupling bolt
    Install the upper coupling bolt through the pinch clamp. Ensure the steering wheel has not rotated from center position. Torque the bolt to specification. Verify both upper and lower alignment marks remain matched, confirming proper steering shaft orientation.
    Torque spec

    Coupling Bolt39 Nm (29 lb-ft)
14. 14

    Check shaft operation
    Gently rotate the steering wheel lock-to-lock (if accessible from under dash) to verify smooth operation with no binding, clicking, or excessive play. The intermediate shaft should move smoothly through its full range. Check that all dust boots are properly positioned and sealed.

Reassembly

1. Reinstall any lower dash panels or covers removed for access
2. Reinstall engine under-shield and splash guards
3. Lower vehicle from jack stands
4. Remove wheel chocks

Verification

• Start the engine and verify no warning lights related to steering system appear on instrument cluster
• Turn steering wheel slowly lock-to-lock while stationary and listen for any unusual noises, clunks, or binding
• Test drive vehicle at low speed in a safe area, checking for proper steering response and centering
• Verify steering wheel returns to center properly after turns
• Re-check both coupling bolt torques after test drive to ensure they remain properly tightened
• Inspect for any signs of interference between the shaft and surrounding components throughout steering range

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