Intermediate Shaft

[Max340]

Just so we're on the same page, this shaft is the piece that connects the steering column with the steering box. Many of us old Mopar nuts know the Int. Shaft as the piece that drives the oil pump and distributor and is geared to the camshaft.



On to the questions:



I had mine replaced under warranty last week. It had a "popping" noise when the suspension would load at a stop and unload when pulling away.



1) why would a shaft that doesn't connect to the suspension make this sort of noise? Trying to make sense of it, so I can look for it in the future.



2) After replacement, I now have what feels like a loose clunk or play in my steering when turning the wheel left or right. Is this normal? I think not, but figured I would ask before going back to the dealer.

 

[tmacc]

Check your track bar and all of the other tie rod ends. Just have someone turn the wheel back and forth while you look at and feel all of the various TR ends. Don't use mopar parts if the ones you have are bad, unless your under warranty. When I had the track bar and drag link end replaced at 26k, the service mgr. said that if a truck is out of warranty, they go to the local parts store for after market parts.

Good luck

Tom

 

[DieselB59]

I have been chasing these ghosts for four and a half years now, and here's what I have found. After replacing the steering box, intermediate shaft (with a Borgeson, and I'd strongly advise everyone to buy a Flaming River shaft after the poor treatment Borgeson gave me when I had a warranty problem with their shaft), and also the steering column, I found that the clunk still existed. Doing further examination, I noticed that traces of brake fluid can and do fall from the reservoir (every single one of them seeps) and drip right onto the steering intermediate shaft at the slip joint. Every time you start, stop and turn your truck, the cab and frame move ever so slightly independent of each other so the truck doesn't crack and stuff. The slip joint is designed to move slightly when this happens. As the brake fluid drops hit the shaft, they are hydrophilic, which means they attract water. That water lets a corrosive film of rust form and the popping is the shaft breaking the film and freeing itself. My solution was to drill the shaft at the joint and put in a zerk fitting so I could pump in some grease at each oil change. Big rigs have them at their slip joints, and some driveshafts on the older trucks also have them on driveshaft slip joints. Ever since I've introduced the grease fitting, the popping and clunking is gone!

 

[Extreme1]

Good One Chris!

How many nights of laying awake did that take to figure out?

 

[DieselB59]

The nights awake were many. About three years worth. It was a mistake that I ever discovered it. I was reaching down past my brake system to prime the fuel transfer pump when I noticed a thick, somewhat grimy film on the shaft. I wondered what could have gotten on it, and began to look around. Looking from under the truck, only the brake reservoir was looming directly above the shaft. I did a complete examination of it and it too was covered on its underside with the same grime. It was then that I went through the boxes in my basement and pulled out my OEM shaft and began cutting it with a grinder/ cut off tool right down the middle so I could see the inner slip joint. Surprise! There was the same grime inside the joint. Even those with rubber/plastic boots on them are susceptible to the same problem. On big rigs, every single thing that has any kind of movement on the chassis and drivetrain has a grease fitting on it. So, I figured, why not on these?

 

[Max340]

DieselB59, I'll bet your advice would have been the solution to my factory installed shaft, that was the one popping.



Now, especially when shut down, I can yank the steering wheel side to side and get a distinct clunk out of the lower end of my column. This is after the dealer replaced the original under warranty.



Tmacc, I'd like to think it is what you say. But since the clunk occurs while shut down and without moving the output end of the steering box, I have to think its in the column. However, your method of checking will eliminate one possibility.

 

[Turbo Thom]

Thanks Chris:

Now I have a new project for the truck. Tap the Borgenson shaft.



Preston