Start roll pin into universal joint prior to installing intermediate shaft on steering column shaft. Install roll pin into just far enough to square roll pin to hole in universal joint. If roll pin is installed too far, universal joint will not slid onto steering column shaft.
Install intermediate shaft on steering shaft until correctly positioned to allow roll pin to be installed in coupler.

Install Remover/Installer, Special Tool 6831-A, through center of roll pin and install knurled nut as show in Fig 1.

Fig 1: Tool Set-Up For Installing Roll Pin (Typical)

Courtesy of DAIMLERCHRYSLER CORP.

1 - SPECIAL TOOL 6831-A

2 - ROLL PIN

3 - KNURLED NUT

4 - INTERMEDIATE SHAFT

5 - UNIVERSAL JOINT

Using Remover/Installer, install roll pin into the coupler until roll pin is fully and evenly installed through both sides of the coupler assembly. See Fig 1.
Remove the steering wheel holder and turn the steering wheel 90° to the right so that the steering wheel is back in the straight-ahead position. Do not allow the steering wheel to turn any further or in any other direction; clockspring center will be lost and clockspring centering procedure must then be performed (Refer to ELECTRICAL/RESTRAINTS/CLOCKSPRING - STANDARD PROCEDURE)
Under the instrument panel, reconnect the intermediate shaft to the steering gear shaft. To do so, align the flats and slide the intermediate shaft onto the steering gear shaft aligning the pinch bolt hole with the notch formed into the steering gear shaft. Install a new pinch bolt in the intermediate shaft coupler, then tighten the pinch bolt to a torque of 44 N.m (32 ft. lbs.). See Figure.
Install lower instrument panel knee bolster onto the lower instrument panel. Install and securely tighten the knee bolster to instrument panel attaching screws.
Install the mirror switch bezel.
Install fuse panel cover on left end of instrument panel.
Install inboard switch bezel. Install mounting screw.
Install center bezel surrounding radio and climate control panel from top cover of instrument panel.
Install silencer panel below steering column knee bolster.
Road test vehicle to ensure proper operation of the steering system.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

Intermediate Shaft: Installation