(Steering)Intermediate Shaft Removal/Installation

Upper Image shows Intermediate Shaft Lower Image shows how the two telescopic ends meet in the middle ,one inside the other.


The two Pinch Bolt ends of the Shaft (Upper one to Steering Shaft/Lower one to Steering Gear Input Shaft)
Note the red marks that I made on the Pinch bolt ends as a alignment guide

The above image shows the newly installed Intermediate Shaft (Steering Shaft U-Joint end)
The below image shows the lower end of the same shaft that connects to the Steering gear Input Shaft which is accessed from under the front end of the jeep.If the old pinch bolt end  does not come off easily,put a wedge/flathead screwdriver in the gap and use something like a pipe wrench to twist it ...then pull off.

Closeup of the Pinch Bolt ends.The top one(connecting to Steering Shaft) is self aligning since the    inside is not symmetrical.The bottom one is symmetrical inside  and fits on a splined shaft(Steering  Gear Input Shaft)Note the gaps that you might have to open wider using a wedge/flathead screwdriver  along with a pipe wrench to twist the wedge/screwdriver so as to enable the"mouth" to open wider which makes the shaft ends easier to remove. 
                               

Note: It takes some effort since the areas you need to work in are a bit tight with little wiggle room. You might have to turn the front tires physically to make Steering Gear Pinch Bolt face down to enable easier pinch bolt Removal/Installation. Use common sense and make the tires face straight forward again after the Pinch Bolt is tight(Bright Marker or Nail Polish will come very handy here )

Tools needed:
Torque wrench
Socket to fit pinch bolts
Large Screwdriver (Not the drink!)

Study the pics first!


REMOVAL

1. Park your Jeep on a level surface and put it in REVERSE GEAR(MANUAL)/PARK(Automatic)
2. Engage the Parking/Emergency Brake.
3. Lift the front end of the Jeep using jackstands and and disconnect the battery.
4. Turn the front wheels to the straight ahead position.
5. Mark the relationship of the Upper U-Joint to Steering Shaft and Lower U-Joint to Steering Gear Input Shaft (Use bright paint or nail polish (don't let your wife catch you doing that!)

6.Loosen and remove the Pinch Bolts at both Upper and Lower U-Joints. (For Shaft Removal You don't have to remove or loosen /re-position the Steering Gear on a YJ,at least I did not have to! )

7.Pry the Intermediate Steering Shaft out of the Steering Shaft U-Joint with a large screwdriver.
Pull the shaft from the Steering Gearbox.

INSTALLATION

A new Intermediate Steering Shaft usually comes compressed lengthwise to save packing space( The design is basically two shafts,one is smaller (connects to Steering Gear) ...and fits inside the bigger one(Connects to Steering Shaft),like a telescope.This is a safety feature so that a driver does not get impaled in case of a front collision!
It takes some effort so either clamp one end to something and pull at the other end till the length between the two pinch bolts is slightly smaller than needed. Position it taking care you align the marks(copy the marks from the old shaft to the new one)and tighten the pinch bolts to 33 Ft-Lbs using a Torque Wrench.