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Originally Posted by ukrkoz
as a matter of fact, i saw your post. appreciate response, thank you.
just to set my ducks in a row:
1. remove plastic panel to access steering shaft
2. possibly, remove 2 bolts holding gas pedal in place. i've seen a post stating that that was not necessary
3. remove in dash intermediate shaft to steering shaft pinch bolt
4. remove, under the hood, upper intermediate shaft to lower intermediate shaft bolt (mine has 2 shafts, one coming out of firewall and one attached to steering gear; that one looks like it has 2 "harmonicas" on either end, probably designed to collapse during head on collision; solid metal); they are connected together and there's a bolt securing connection, about midway from firewall to steering gear.
5. from under the dashboard, press intermediate shaft down on steering shaft, to slide it off it; i am assuming that there's some sort of compressing structure in it that permits so, as it will not slide down the lower intermediate shaft, it's 100%, i know from my 1st attempt. i never tried to remove the upper sshaft, as, like i said, dealer sold me lower one as "the most popular one". i have no idea if the upper one is stuck, never had my hands on it.
6. slide intermediate shaft off the lower intermediate shaft and remove it into the cabin.
did i get it right? will be fun to do, considering that i'm 6'5''. 'ts ok, that clunk became a solid "pebble in the shoe".
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1) - I don't remember having to remove any plastic panels (I assume you mean inside the cab) - I could see the upper bolt without removing anything. I just looked - underneath the dash at the firewall, you'll see a small u-joint and then the bolt you need to undo.
2) - 2 bolts for the gas pedal - you might get away without doing this, but it was so easy, I did it anyway.
3) - yep - that's the bolt just inside the upper intermediate shaft u-joint
4) - yep - the bolt you want under the hood is just above the upper bellow shaped part of the lower shaft.
5) - I found it easier to unbolt the lower bolt, push upwards on the intermediate shaft 'til it clears, and then unbolt the upper bolt inside the cab. I'd be pretty sure it's the upper (intermediate) shaft that you want to replace - it's the one that's causing all the "clunking" problems. This shaft has a sliding splined shaft inside a cylinder that moves in and out. This is how your steering wheel can remain in place while the front suspension goes over bumps. It moves enough to clear so it can be removed. If yours is too stiff to move, it's probably why you're getting the clunking. You may need to force it.
6) - I pulled mine out through the firewall from under the hood - I think it's easier.
My truck is an '03 4x4 1500 - yours could be different...
Good luck! Art