Intermediate Steering Shaft

Removal Procedure

Tools Required
- J 42640 Steering Column Anti-Rotation Pin

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.





1. Mark the relationships of the intermediate shaft to the following components in order to ensure proper installation:
- The steering column shaft
- The steering gear input shaft
2. Disable the SIR system. Refer to Disabling the SIR System in Restraint Systems.
3. Install the J 42640 in the steering column lower access hole.
4. Remove the upper fan shroud. Refer to Fan Shroud Replacement - Upper in Cooling System.





5. Remove the bolts from the underhood electrical center and set aside.





6. Remove the intermediate shaft boot from the cowl.





7. Remove the pinch bolt (3) from the intermediate shaft (2) at the steering column shaft (1).
8. Remove the intermediate shaft boot from the steering gear.
9. Remove the intermediate shaft boot from the vehicle.





10. Remove the pinch bolt from the intermediate shaft at the steering gear.
11. Remove the intermediate shaft.

Installation Procedure
1. Align the flat on the intermediate shaft with the flat on the steering gear shaft.
Observe the marks that were made before the disassembly.
Install the intermediate shaft to the steering gear shaft.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the intermediate shaft pinch bolt.
Tighten the intermediate shaft pinch bolt to 41 Nm (30 ft. lbs.).





3. Install the intermediate shaft boot over the intermediate shaft. Do not secure the boot to the steering gear.





4. Align the flat on the intermediate shaft with the flat on the steering column shaft. Observe the marks that were made before the disassembly. Install the intermediate shaft (2) to the steering column shaft (1).
5. Install the intermediate shaft pinch bolt (3).
Tighten the intermediate shaft pinch bolt to 41 Nm (30 ft. lbs.).





6. Measure the intermediate shaft angle. For RWD, the angle must be 38-40 degrees.





7. Measure the intermediate shaft angle. For A4WD, the angle must be 38-40 degrees.
8. Install the intermediate shaft boot to the steering gear.
9. Install the intermediate shaft boot cowl with the 4 screws.





10. Install the underhood electrical center.
Tighten the bolts to 5.5 Nm (4 ft. lbs.).
11. Install the upper fan shroud. Refer to Fan Shroud Replacement - Upper in Cooling System.





12. Remove the J 42640.
13. Enable the SIR system. Refer to Enabling the SIR System in Restraint Systems.