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Included in this segment are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of repair-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.
Note:
- Always wear eye protection, and follow proper safety precautions, when working with power tools or pneumatic tools.
Materials Required:
In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.) and the snow-plow and hitch kits, the only specialty tools that will be needed for the projects in this episode are a fish wire, engine-degreaser spray, steering lube-kit and a level. An air-compressor and set of pneumatic tools is optional, but may be very helpful for this project.
Procedure:
- To service the intermediate steering shaft, it must first be removed from the vehicle.
Note:
- To avoid damaging the airbag clock-spring connector, the steering wheel must be centered and locked before we remove the intermediate steering shaft.
- Remove the bolt on the end of the shaft located under the dash. Working room is tight here, but once the nut is removed from the shaft bolt, the bolt can be pushed out the side of the shaft, and the shaft then pulled off the steering column.
- Removing the end of the intermediate shaft that is near the engine may seem easier. The 20-millimeter bolt and shaft clamp are removed from the end of the shaft that connects to the steering gear box. The other end of the shaft has a universal joint that is too big to pass through the firewall rubber boot, so the intermediate shaft is pulled back through the firewall.
Note:
- When removing or reinstalling the shaft, make sure that it is compressed all the way.
- Clean all of the existing lubricant off the intermediate shaft using degreaser, and check it for wear.
- Fully extend the shaft and carefully remove the clip using needle-nosed pliers.
- With the clip removed, use the filled syringe from the lube kit and put the entire contents of the syringe in the shaft.
- With the grease in place, place the plug (provided with the kit) in the end of the shaft, and press it down tight.
- Compress the shaft a couple of times to evenly distribute the grease inside the shaft.
- Remove the plug and reinstall the clip.
- The procedure for reinstalling the shaft on the vehicle is the reverse of the steps for removal. First the shaft is inserted into the firewall boot from underneath the dash and pushed down toward the engine.
- The end of the shaft just under the steering wheel is connected and bolted in.
- Then the other end of the shaft, near the steering gear box, is bolted in with the clamp that holds the nut.
- With the shaft, reinstalled, verify the repair by turning the steering wheel lock to lock. If the TSB procedure worked properly, and the part was reinstalled properly, there should be no binding or "popping" when the steering wheel is turned.
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