Intermediate steering shaft diy replacement – question – toyota sienna forum –

-Ensure wheels and SW are still perfectly straight as mine shifted ever so slightly in the process of jacking the car up, forcing me to reinstall the lower portion of the ISS after a test drive when I noticed the SW was not perfectly straight.

-Back in the cabin, slide the ISS off the SW shaft and then pull the ISS through the firewall. Remove the metal retaining ring and set it aside (the included ring with the Dorman kit did not fit properly so I reused the factory ring – before bolting anything down, check whether the new ring works or if you need the old ring).

-Note: this is where things got interesting: I had to remove the air box and air filter from inside the engine compartment and take my 18" crow bar and 3 lb hammer and carefully whack the ISS shaft on from above.

The crow bar was fed through the brake actuator and that’s why you have to whack it carefully or risk doing expensive damage to your car.

-Note: prior to installation of the new ISS, it may have been possible to spread the recess splined female part of the ISS shaft so that it accepts the male shaft on the steering rack much easier. The pinch bolt would ensure it tightens back down were you to do this but I already had the shaft bolted in from above and was in ‘full steam ahead’ mode before this thought occurred to me. I checked with a mechanic after install whether the fact that it wasn’t seated as far as the factory installation had been and he told me that this is often the case with these repairs, especially with aftermarket, non-OEM ISSs. As long as the shaft is seated down to the bottom of the splines and the pinch bolt can be tightened, then you are good to go.

-Once the ISS is seated on to the rack, tighten the pinch bolt to 27 foot pounds. Again, I had to use something other than my torque wrench so I got it as tight as I could with the small gearwrench 12mm wrench I was able to fit in there. I threw some blue JB Weld on it for peace of mind.

-Put it all back together and test drive it. If the wheel is not perfectly straight, you’ll have to redo the lower portion of the install. To do this, figure out what your new "straight" is for your wheels. Set your wheels to this angle, jack the car up, unbolt and remove the lower part of the ISS and have someone hold the wheel dead straight while you drop the lower ISS female shaft onto the male steering rack shaft. Tighten pinch bolt and test again.

-The new shaft fixed the clunking in the SW I was having. In fact, it drives and handles like a new car. Apparently, the old ISS was allowing road vibrations up the wheel that I had simply gotten used to. The difference is night and day. When I gave a two-handed twist/stress test to the old shaft, it would give in odd ways that didn’t feel right.

-Prior to doing this, a mechanic told me that this problem wouldn’t progress beyond what it was and that I could leave it. But I’m the type of person who does all of my preemptive and necessary maintenance and repairs. This falls somewhere in between preemptive and necessary for me and, for only $140, it was worth it to have a car that drives like new again.

-A Toyota parts department told me that the 2006 or 2007 and later shafts cannot be re-greased as they are sealed units. I’m fairly certain that this is not so as it would not be hard to get grease up into the long part of the old shaft where the sliding union is. I don’t know if this would make a difference or, if it did, whether it would be a lasting one. Others online have reported that the regreasing repair is temporary and that the clunking comes back. Without having first hand knowledge before the project I took Toyota at their word that the old unit is more or less toast and went ahead and ordered the new Dorman part from an online vendor. Were I to do it again, I might try to grease the OEM ISS to coax more life out of it. But the Dorman claims to be an updated part that fixes the OEM problem so in the end I’m happy I went ahead and replaced it. Only time will tell now.