Steering Shaft - Intermediate

This procedure covers the removal and replacement of the intermediate steering shaft on a 2007 Ram 3500 with 5.9L Cummins diesel engine, addressing issues like clunking noises or excessive play in the steering column.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn steering wheel to center position and lock it using steering wheel lock or have helper hold firmly
4. Raise front of vehicle with floor jack and support securely on jack stands at frame rails
5. Allow steering components to cool if vehicle was recently driven

Procedure

1. 1

   Access intermediate shaft at steering column
   From inside the cab, locate the intermediate steering shaft connection at the base of the steering column above the floor pan. You may need to remove the lower dash panel or knee bolster for better access depending on trim level. The upper coupler connects the intermediate shaft to the steering column shaft.
2. 2

   Mark upper shaft alignment
   Using a white paint marker, make alignment marks across the upper coupler where the intermediate shaft connects to the steering column shaft. Mark both the shaft and the coupler in a way that clearly shows rotational alignment. This is critical for reassembly to maintain steering wheel centering.
3. 3

   Remove upper coupler bolt
   Locate the pinch bolt on the upper coupler. This is typically a 15mm bolt threaded into the coupler clamp (not a through-bolt with a separate nut). Spray with penetrating oil if corroded. Hold the nut with a wrench while loosening the bolt with a socket. Remove the bolt completely and retain hardware if reusing.
   ⚠Ensure steering wheel remains locked in center position. Movement at this stage can damage the clockspring.
4. 4

   Separate upper coupler
   Using a flat blade screwdriver, carefully pry open the slot in the upper coupler clamp. Do not pry against the steering column shaft itself. Once the clamp is spread slightly, tap the coupler with a soft hammer or brass drift to break it free from the column shaft. The intermediate shaft should now be free at the top but still connected at the steering gear.
5. 5

   Access lower shaft connection at steering gear
   Working from underneath the vehicle, locate the lower connection of the intermediate shaft to the steering gear input (worm) shaft. The frame-mounted steering gear is on the driver's side of the frame rail; access the lower coupler at the top of the gear input shaft. The lower coupler will have a pinch bolt similar to the upper connection.
6. 6

   Mark lower shaft alignment
   Using the paint marker, make clear alignment marks across the lower coupler where the intermediate shaft connects to the steering gear input shaft. Mark both the shaft and coupler to show rotational position. These marks must be clearly visible for reassembly.
7. 7

   Remove lower coupler bolt
   Remove the pinch bolt from the lower coupler using the appropriate socket (typically a 15mm head; verify size before applying force). The bolt may be accessed from different angles depending on component clearance. Spray with penetrating oil if necessary. Remove the bolt and nut completely.
8. 8

   Separate lower coupler and remove shaft
   Spread the lower coupler clamp slot with a flat blade screwdriver. Tap the coupler with a soft hammer to break it free from the steering gear input shaft splines. Once free, maneuver the intermediate shaft assembly down and out from between the steering column and steering gear. Note the routing path for installation.
9. 9

   Inspect components
   Inspect the steering column shaft and steering gear input shaft for damage, wear, or corrosion. Check splines for wear or damage. Clean both shafts with a wire brush if necessary. Inspect new intermediate shaft to ensure couplers move smoothly through their range of motion and that there is no binding or excessive play.
10. 10

    Install new intermediate shaft to steering gear
    Position the new intermediate shaft assembly and slide the lower coupler onto the steering gear input shaft. Align the coupler with the shaft splines and push firmly until fully seated. Rotate the intermediate shaft to align your previously made reference marks or ensure proper clocking if replacing due to wear.
    ⚠Verify steering wheel is still locked in center position before proceeding.
11. 11

    Install lower coupler bolt
    Install the lower coupler pinch bolt and nut. Align the bolt through the clamp and tighten by hand first. Torque the bolt to manufacturer specifications (approximately 21 ft-lbs / 28 Nm for this platform). Verify the coupler clamp gap closes and the connection is secure without crushing the clamp.
12. 12

    Connect upper coupler to steering column
    Working from inside the cab, guide the upper end of the intermediate shaft up to the steering column shaft. Align the upper coupler with the column shaft splines. Match your alignment marks from disassembly. Push the coupler firmly onto the column shaft until fully seated.
13. 13

    Install upper coupler bolt
    Install the upper coupler pinch bolt and nut through the clamp. Verify alignment marks are still matched before tightening. Hand tighten first, then torque to manufacturer specifications (approximately 21 ft-lbs / 28 Nm for this platform). Ensure a secure connection without damaging the clamp.
14. 14

    Lower vehicle and final checks
    Remove jack stands and carefully lower the vehicle to the ground. Remove wheel chocks. Unlock or release the steering wheel. Reinstall any interior panels or covers that were removed for access.

Reassembly

1. Ensure both upper and lower coupler pinch bolts are properly torqued and clamp gaps are closed
2. Verify alignment marks are matched at both connections to maintain steering wheel centering
3. Reinstall any interior trim panels removed during access
4. Confirm steering wheel rotates smoothly through full range without binding

Verification

• Start engine and verify power steering operates normally without unusual noises
• Turn steering wheel lock-to-lock slowly while stationary, checking for binding, clunking, or unusual resistance
• With engine running, check for vibration or noise from intermediate shaft area
• Drive vehicle at low speed and verify steering wheel is centered when traveling straight
• Test steering response and verify no play or looseness in steering system
• Recheck all connection points after test drive to confirm bolts remain tight

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle