Intermediate Steering Shaft Replacement C3500HD

Tools Required

J 42640 Steering Column Anti-Rotation Pin

1. Set the front wheels in the straight-ahead position.



2. Lock the steering column through the access hole in the lower steering column shroud using J 42640 .



3. Remove the shield from the steering gear.
4. Mark the relationship of the intermediate shaft components in order to assure proper installation.

4.1.	Mark the relationship of the upper intermediate shaft to the lower intermediate shaft.

4.2.	Mark the relationship of the lower shaft coupler to the steering gear input shaft.

5. Remove the nut and the bolt from the upper to lower shaft connection.
6. Remove the bolt from the lower shaft coupler.
7. Remove the intermediate shaft assembly.

Slide the shaft towards the dash in order to get the lower shaft coupler clear of the steering gear input shaft.

8. Slide the intermediate shaft down out of the upper shaft.

1. Install the upper end of the intermediate shaft into the upper shaft.
2. Install the lower end of the intermediate shaft coupler.

2.1.	If the same shaft is being reinstalled, align the marks made during the removal procedure.

2.2.	Install the lower end of the intermediate shaft coupler onto the steering gear worm shaft.

3. Install the bolt to the lower shaft coupler.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the bolt and the nut to the upper end of the shaft.

Tighten

•	Tighten the upper nut to 62 N·m (46 lb ft).

•	Tighten the coupler pinch bolt to 30 N·m (22 lb ft).

5. Install the shield onto the steering gear.



6. Unlock the steering column by removing J 42640 from the steering column lower shroud access hole.