Steering Shaft: Service and Repair

STEERING COLUMN INTERMEDIATE SHAFT

REMOVAL
1. Remove fuse panel cover from left end of instrument panel.
2. Remove center bezel surrounding radio and climate control panel.
3. Remove screw attaching bezel to instrument panel behind climate control panel. Remove bezel.
4. Remove outside mirror switch bezel from instrument panel.
5. Remove silencer panel below steering column knee bolster.
6. Remove screws attaching knee bolster to instrument panel.
7. Lower knee bolster and disconnect connectors from rear, then remove bolster.
8. Position front wheels of vehicle in the straight-ahead position.





9. Disconnect the intermediate shaft from the steering gear shaft. To do so, remove the pinch bolt from the intermediate shaft coupler (Fig. 15), then slide the intermediate shaft up and off the steering gear shaft.
10. Turn the steering wheel 90° to the LEFT. This is done to allow proper roll pin removal tool installation.
11. Using a steering wheel holder, lock the steering wheel in this position. This is done to keep the clockspring from turning, losing its center. It will also help hold the shaft steady while removing the roll pin.





12. Install Remover/Installer, Special Tool 6831-A, through center of roll pin in intermediate shaft's universal joint and install knurled nut (Fig. 16).
13. While holding hex on end threaded rod, tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the intermediate shaft's universal joint.
14. Using a screwdriver inserted between the shaft's universal joint and the steering column lower mounting bracket, gently pry intermediate shaft off steering column shaft.

INSTALLATION
1. Start roll pin into universal joint prior to installing intermediate shaft on steering column shaft. Install roll pin into just far enough to square roll pin to hole in universal joint. If roll pin is installed too far, universal joint will not slid onto steering column shaft.
2. Install intermediate shaft on steering shaft until correctly positioned to allow roll pin to be installed in coupler.





3. Install Remover/Installer, Special Tool 6831-A, through center of roll pin and install knurled nut as shown (Fig. 17).
4. Using Remover/Installer (Fig. 17), install roll pin into the coupler until roll pin is fully and evenly installed through both sides of the coupler assembly.
5. Remove the steering wheel holder and turn the steering wheel 90° to the right so that the steering wheel is back in the straight-ahead position. Do not allow the steering wheel to turn any further or in any other direction; clockspring center will be lost and clockspring centering procedure must then be performed
6. Under the instrument panel, reconnect the intermediate shaft to the steering gear shaft. To do so, align the flats and slide the intermediate shaft onto the steering gear shaft aligning the pinch bolt hole with the notch formed into the steering gear shaft. Install a new pinch bolt in the intermediate shaft coupler (Fig. 15), then tighten the pinch bolt to a torque of 44 Nm (32 ft. lbs.).
7. Install lower instrument panel knee bolster onto the lower instrument panel. Install and securely tighten the knee bolster to instrument panel attaching screws.
8. Install the mirror switch bezel.
9. Install fuse panel cover on left end of instrument panel.
10. Install inboard switch bezel. Install mounting screw.
11. Install center bezel surrounding radio and climate control panel from top cover of instrument panel.
12. Install silencer panel below steering column knee bolster.
13. Road test vehicle to ensure proper operation of the steering system.