2nd Gen Tacoma Intermediate Steering Shaft Replacement and Review

I see it as you have 2 options. Being that the sleeve/clamp didn't move on the upper shaft, you could reinstall as is OR remove the upper shaft which isn't difficult, and soak with Penetrant, put in a vise and BFH the sleeve/clamp off, clean up the splines and inspect further. I'd recommend using a torch and applying some heat before getting too carried away with the hammer. Heat is your friend here, followed by a good penetrating oil.

I'd refrain from "Spreading" the sleeve/clamp as much as possible, as it'll only weaken it. Remove as much surface rust as possible, and go with the heat and Penetrant method. If you're able to put it in a vise, with the sleeve/clamp on top of the vise Jaws, and the shaft hanging below the vise, that'll give you something to drive against and hold it. Use a punch and drive the shaft out of the Clamp with a good size hammer.

 

Thanks for the reply Yancey. I did a bit more looking around at parts and it looks like the one I may have buggered up is 45220-04010, what Toyota online shops call the steering shaft, but the parts manual calls the intermediate shaft. It kinda looks like one piece though, so I'm not sure what the deal is with seeing the splines on it? Maybe the smaller diameter on the left is press fit into the larger diameter? I'll get it out this evening after work and take the punch and vise approach on the sleeve, just so I can get as much rust off as possible. As for the steering shaft, we'll see if I can get it back to the right length.

 

Seeing the splines on the upper shaft in your picture isn't that big of a concern, as the shafts do slide I'm and out a bit, which is what allows your steering wheel to have the Telescoping adjustment. If I were you, I'd take the plastic trim beneath the column in the cab off, and there are 2 nuts the hold the column to the dash structure. If you take them off, you can lower the column to the seat, and get a really good look at everything. Not a difficult thing to do by any means, but I'd make sure the battery is disconnected, just as a precaution, due to the airbag.

 

Thanks for the help Yancey! Got it wrapped up today. The sleeve was pretty bad, so no wonder I couldn't get it to slide. After wire brushing it and cleaning it up, the corrosion was still pretty welded on and hard to remove without spline damage. I opted to make a quick trip up to my stealership.

 

Thanks for the thread, instructions and photos were helpful.