Intermediate Shaft

Intermediate Shaft

REMOVAL

CAUTION: After the steering column intermediate shaft is removed at either the steering gear or steering column, be sure the steering column shaft is not rotated. If the steering column shaft is allowed to rotate freely, damage to the clockspring will occur.

1. Raise the vehicle.





2. Install Remover, Special Tool 6831A, through the center of the roll pin and the intermediate shaft coupler at the steering gear. Install the special knurled nut.
3. Remove the roll pin from the intermediate shaft coupler by performing the following:





a. Hold the threaded bolt on the Remover from rotating using a wrench.
b. Using a second wrench, tighten the nut against the sleeve of the special tool. This will pull the roll pin out of the coupler of the intermediate steering shaft.
c. Remove the tools.
4. Remove the intermediate shaft from the power steering gear by sliding it off the gear's input shaft.





5. Remove the bolt from the flex joint on the intermediate shaft at the steering column shaft.
6. Slide the flex joint off the end of the steering column shaft and remove the steering column intermediate shaft from the vehicle.

INSTALLATION

1. Align the splines and slide the steering column intermediate shaft flex joint onto the steering column shaft.
2. Install the pinch bolt in the flex joint. Tighten the pinch bolt to a torque of 41 Nm (30 ft. lbs.).
3. Align the master spline on the intermediate shaft lower coupler with the master spline on the power steering gear input shaft. Slide the intermediate shaft coupler onto the input shaft until fully seated.
4. Start the roll pin into the intermediate shaft coupler by lightly tapping it with a soft face hammer.





5. Install the Installer, Special Tool 6831A, through the intermediate shaft lower coupler and roll pin and install the special knurled nut.
6. Place a wrench on the threaded bolt head of the Installer to keep it from rotating. Using a second wrench, tighten the nut against the sleeve of the special tool. This will pull the roll pin into the intermediate steering shaft coupler. Install roll pin until it's exposed end is flush with the side of the coupler. Remove the tools.
7. Lower the vehicle.
8. Road test vehicle to verify proper operation of the steering system.