This procedure covers the removal and replacement of the intermediate steering shaft on a 2019-2024 Toyota RAV4 with 2.5L I4 engine and electric power steering.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Use OEM specification
• Lower steering shaft pinch bolt × 1 — Replace if damaged or corroded

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Turn ignition to ON position and center the steering wheel precisely
4. Turn ignition OFF and remove key
5. Install steering wheel lock or insert locking pin through steering wheel and column to prevent rotation
6. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
7. Raise front of vehicle and support securely on jack stands at manufacturer-specified lift points
8. Remove front wheels if additional access is needed (optional for most cases)

Procedure

1. 1

   Access steering shaft area
   Remove the driver's side lower dashboard trim panel and knee bolster to access the upper steering shaft connection. Remove plastic fasteners and screws as needed. Set aside panels in a clean area to prevent damage.
2. 2

   Mark steering shaft alignment
   Using a white paint marker or tape, mark the alignment relationship between the upper steering shaft (column shaft) and the intermediate steering shaft at the upper U-joint. Also mark the relationship between the intermediate shaft and the lower steering gear input shaft at the lower U-joint. These marks are critical for proper reassembly.
3. 3

   Disconnect upper steering shaft
   Locate the upper pinch bolt connecting the steering column shaft to the intermediate shaft U-joint. Remove the pinch bolt completely. Note the bolt orientation for reinstallation. Gently separate the connection by pulling the intermediate shaft downward while supporting it.
   ⚠Do not use excessive force or prying that could damage the steering column or U-joint. A slight twisting motion while pulling may help separate the splined connection.
4. 4

   Access lower steering connection
   Working from underneath the vehicle, locate the lower steering shaft connection at the steering gear input shaft. This is typically accessed from the driver's side wheel well area. Clean any dirt or debris from the pinch bolt area.
5. 5

   Remove lower pinch bolt
   Remove the lower pinch bolt that secures the intermediate steering shaft to the steering gear input shaft. Apply penetrating oil if the bolt is corroded. Note the bolt orientation and any washers or spacers present.
   ℹ️Support the intermediate shaft to prevent it from falling when the lower connection is released.
6. 6

   Remove intermediate steering shaft
   Carefully pull the intermediate shaft away from the steering gear input shaft to separate the splined connection. Maneuver the shaft through the firewall opening and remove it from the vehicle. Inspect the shaft for wear, damage, looseness in the U-joints, or collapsed/deteriorated rubber isolation components.
7. 7

   Inspect steering components
   With the shaft removed, inspect the steering column shaft splines and steering gear input shaft splines for wear, damage, or corrosion. Check the firewall grommet for tears or deterioration. Clean the splined connections with a wire brush if necessary.
8. 8

   Install new intermediate shaft
   Position the new intermediate steering shaft and insert it through the firewall opening. Align the lower end with the steering gear input shaft, matching your alignment marks. Slide the shaft onto the steering gear input shaft splines, ensuring proper engagement (usually 3/4 to 1 inch of spline engagement).
   ⚠Verify the steering wheel has not moved from the centered, locked position. If it has moved, do not continue until it is properly re-centered.
9. 9

   Install lower pinch bolt
   Install the lower pinch bolt through the intermediate shaft and steering gear input shaft yoke, ensuring the bolt passes through the groove in the input shaft. Align the shaft according to your reference marks. Torque the pinch bolt to specification. Note: Use the Mounting Bolts specification for pinch bolts unless otherwise specified.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Connect upper steering shaft
    Align the upper end of the intermediate shaft with the steering column shaft, matching your alignment marks. Slide the connection together ensuring proper spline engagement. The U-joint should align properly with the column shaft.
11. 11

    Install upper pinch bolt
    Install the upper pinch bolt through the U-joint yoke and column shaft, ensuring it passes through the groove in the column shaft. Align according to reference marks. Torque the pinch bolt to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
12. 12

    Verify shaft installation
    Check that both upper and lower connections are properly secured with pinch bolts torqued correctly. Verify there is no binding or interference throughout the shaft length. Ensure the firewall grommet is properly seated around the shaft.

Reassembly

1. Reinstall driver's side lower dashboard trim panel and knee bolster with all fasteners
2. Remove steering wheel lock or locking pin
3. Reconnect negative battery terminal
4. If wheels were removed, install wheels and torque lug nuts to specification in a star pattern
5. Lower vehicle to ground

Verification

• With vehicle on ground and engine running, turn steering wheel slowly from lock to lock while stationary, listening for any clunking, binding, or unusual noises
• Check that steering wheel returns to center properly after turning
• Verify steering wheel is still centered when driving straight
• Test drive vehicle at low speed in a safe area, checking for smooth steering operation without play, vibration, or noise
• Verify no abnormal steering effort or resistance
• Check that no warning lights are illuminated on the dashboard (EPS warning light should be off)
• If EPS warning light is on or steering feels abnormal, perform EPS system initialization with a compatible scan tool per manufacturer procedure

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