Pull the front spare tire well. Remove dash lower trim panel below steering column. Remove the four 15mm fastners holding the column to the support. Remove the two 11mm bolts holding the intermediate shaft to the column and the rack. Pull the column backward (toward seat) to remove the shaft.
So the column does need to be lowered to get the shaft out?
Also - I know the telescoping shaft inside the steering column is fixed together with a plastic plug - could something similar be used here to lock the two sections together? I was thinking a nylon bolt so it would still shear in a collision.
I removed the shaft today. Like the shaft inside the steering column, the intermediate shaft has two plastic pins that are presumably supposed to keep the shaft free of slop but still allow it to telescope in a collision. Clearly, since there's movement in my joint, those two plastic pins have failed.
It would be easy to drill a small hole through the assembly and install a low strength bolt as a way to repair. Any comment on whether this is a bad idea?
The inner shaft and outer housing of the intermediate shaft fit tightly together with no axial play, as they have a 'double D', or barrel shape. The nylon locking pin does not reduce slop in any way. Only two reasons for the nylon lock... 1. Ease assembly on the production line 2. Determine if the shaft was involved in a collision
If there is any axial play (the inner shaft rotating in the outer housing), the intermediate shaft is worn out and should be replaced.
There's a bit of looseness in the steering despite reworking the suspension and steering rack. Holding the intermediate shaft in hand I can feel a small amount of axial and rotational play in the telescoping joint. I assume it should be tight.
I ended up putting the shaft in a press and squeezing it to get it tight. No more axial or rotational play. Sprayed some teflon lubricant in there, should have no problem telescoping in a crash.
Just for reference, I got the shaft out by loosening up the steering rack mounting bolts but without disconnecting the tie rod ends. This provides enough room to maneuver the shaft out.
