Steering Coupler

Replace the steering coupler (intermediate shaft) that connects the steering column to the steering gear on a 2007 Ram 3500 with 5.9L Cummins diesel engine.

Warnings

Tools required

Parts

• Steering coupler (intermediate shaft) × 1 — Use OEM specification
• Steering coupler pinch bolt (upper) × 1 — Use OEM specification
• Steering coupler pinch bolt (lower) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Chock rear wheels securely
3. Turn steering wheel to center position with wheels pointing straight ahead
4. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
5. Raise front of vehicle with floor jack and support on jack stands at frame rails
6. Remove front skid plate if equipped (four 15mm bolts)
7. Apply penetrating oil to steering coupler pinch bolts and let soak for 10-15 minutes

Procedure

1. 1

   Access upper coupler connection
   Working from inside the cab, remove the lower steering column cover by removing the two Torx T50 screws. Tilt the cover down and pull forward to remove. You may need to lower the tilt steering column to its lowest position for better access. Locate the upper steering coupler pinch bolt where the intermediate shaft connects to the steering column shaft.
2. 2

   Mark upper alignment
   Using a white paint marker or grease pencil, mark the alignment relationship between the steering column shaft and the steering coupler at the upper connection. Make marks on both the shaft and the coupler that align with each other. This is critical for proper reassembly and maintaining steering wheel position.
3. 3

   Remove upper pinch bolt
   Using the correct socket for the upper coupler pinch bolt head (verify size — commonly 13mm), remove the upper steering coupler pinch bolt. This bolt clamps the coupler to the steering column shaft. Do not remove the coupler from the shaft yet. If the bolt is seized, apply additional penetrating oil and allow to soak.
4. 4

   Secure steering wheel
   Use a steering wheel holder or secure the steering wheel to the seat with a bungee cord to prevent it from rotating. This prevents damage to the clockspring during the repair.
5. 5

   Access lower coupler connection
   Working from underneath the vehicle, locate the lower end of the steering coupler where it connects to the steering gear (steering box) input shaft. The steering gear is mounted to the driver-side frame rail; the coupler connects at its input shaft on top of the gear. You may need to turn the front wheels slightly (by hand, working underneath) to access the pinch bolt, but avoid excessive rotation.
6. 6

   Mark lower alignment
   Mark the alignment relationship between the steering gear input shaft and the lower steering coupler with a paint marker. Make clear reference marks on both the shaft and coupler that align with each other.
7. 7

   Remove lower pinch bolt
   Using the correct socket for the lower coupler pinch bolt head (verify size against OEM specification), remove the lower steering coupler pinch bolt from the steering gear input shaft. This bolt may be very tight. If necessary, use penetrating oil and an impact wrench. Keep track of any washers or spacers.
8. 8

   Separate lower coupler connection
   Using a flat blade pry bar, carefully spread the lower coupler clamp slot to separate it from the steering gear input shaft. Insert the pry bar into the clamp slot and gently twist to expand the clamp. The coupler should slide off the splined shaft. If stubborn, tap gently with a plastic mallet while prying the clamp open.
9. 9

   Remove steering coupler
   Working from inside the cab, spread the upper coupler clamp with a pry bar if needed and slide the entire steering coupler assembly down and off the steering column shaft. You may need to collapse or rotate the coupler slightly to maneuver it through the firewall opening and past obstructions. Remove the coupler from underneath the vehicle.
10. 10

    Inspect and prepare new coupler
    Inspect the steering column shaft and steering gear input shaft splines for wear or damage. Clean both shafts with a wire brush. Compare the new steering coupler to the old one to verify correct replacement. Check that both clamp bolts are loosened on the new coupler to allow installation over the shafts.
11. 11

    Install new coupler
    Position the new steering coupler from underneath the vehicle and guide it up through the firewall area. Slide the upper end onto the steering column shaft, aligning your reference marks to maintain proper steering wheel position. The coupler should slide onto the splines easily. Do not force it.
12. 12

    Install upper pinch bolt
    Verify the alignment marks are matched at the upper connection. Install the new upper pinch bolt through the coupler clamp and tighten by hand. Position the clamp gap opposite the pinch bolt for proper clamping action. Tighten the pinch bolt firmly using a 13mm socket. The upper coupler pinch bolt should be torqued to the OEM specification (approximately 21 ft-lbs / 28 Nm for an M8 pinch bolt — verify against factory service manual). Tighten using the correct socket for the bolt head.
13. 13

    Connect lower coupler
    Working from underneath, slide the lower end of the steering coupler onto the steering gear input shaft, aligning your reference marks. Ensure the splines are fully engaged and the coupler is seated completely on the shaft.
14. 14

    Install lower pinch bolt
    Verify alignment marks are matched at the lower connection. Install the new lower pinch bolt with any washers through the coupler clamp. Position the clamp gap opposite the pinch bolt. Torque the lower pinch bolt to the OEM specification (verify against factory service manual — commonly around 21 ft-lbs / 28 Nm) using the correct socket for the bolt head.

Reassembly

1. Reinstall the lower steering column cover inside the cab with the two Torx T50 screws
2. Reinstall front skid plate if equipped
3. Remove jack stands and lower vehicle to ground
4. Reconnect negative battery cable
5. Remove steering wheel holder or bungee cord

Verification

• Start the engine and verify power steering operates normally without noise
• Turn the steering wheel lock to lock while stationary and check for binding, clicking, or unusual noises from the coupler area
• Verify steering wheel is centered with wheels pointing straight ahead
• Test drive the vehicle at low speed and verify steering response is normal with no play or vibration
• Check that airbag warning light functions normally (illuminates briefly at startup then turns off)
• Inspect coupler connections from underneath for proper seating and bolt tightness after test drive

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