Steering intermediate shaft and flexible coupling - removal and refitting

Removal
1 Apply the handbrake, jack up the front of the vehicle and support on axle stands.

2 Working in the engine compartment, unscrew the bolt securing the intermediate shaft to the inner column, swivel the clamp plate to one side, and disconnect the intermediate shaft.

3 Unscrew and remove the clamp bolt securing the flexible coupling to the steering gear (see illustration).

26.3 Intermediate shaft-to-steering gear flexible coupling
26.3 Intermediate shaft-to-steering gear flexible coupling

4 Mark the coupling in relation to the pinion, then pull off the intermediate shaft and remove it from the vehicle. The pinion has a master spline, but making alignment marks will aid refitting (see illustration).

26.4 Master spline location on the steering gear pinion and intermediate
26.4 Master spline location on the steering gear pinion and intermediate shaft coupling

Refitting
5 Refitting is a reversal of removal, but align the marks on the coupling and pinion, and tighten all bolts to the specified torque.

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