77 intermediate steering shaft collapses

[Idahododgeram]

Hi all, I'm new to the site and have searched but didn't find the specific answer I was looking for. I have a '77 CJ5 and am doing a complete overhaul on the steering column (among other things). The intermediate steering shaft has 2 plastic pins that are meant to shear in the event of a front end collision. When I pulled mine out it collapses so the pins must have sheared at some point. I don't believe the Jeep to have ever been in an accident so it could just be old age.

Should I just replace the shaft or can I install new pins and re assemble it? I read somewhere that someone replaced the pins with nylon screws. I know the shaft is just over $100 to replace but there is nothing else wrong with it and a $100+ saved is money that can go elsewhere.

Any help/insight/info would be appreciated.

 

[Torxhead]

Replacing the pins with plastic screws would not be as strong as the pins unless you drill out the holes and install plastic screws that are larger than the pins. Aluminum pins would be another option. Just using metal screws would probably be the quickest fix in the existing holes. I would think it would be a matter of just what you can find. Check for excessive play in the steering shaft when you get it assembled. Another wear item is the steering shaft coupler.

 

[Idahododgeram]

Thanks Torxhead. I am waiting on new upper and lower bearings before I can put this jigsaw puzzle back together. A new coupler is on order as well. No sense fixing some of the steering and not fixing the other wearables.

 

[Torxhead]

When I replaced the bearings in my '86, I noticed the lower bearing was in poor condition along with a lot of dirt in it. I am not sure if it did need to be that exposed as it was but I did cover outside area with electrical tape.

 

[Posi]

I used 2 tack welds on both sides of the shaft.
The guys has been driving the Jeep on and offroad for three years they have held up. However, the tacks are not strong enough for a head on crash and will collapse as they should.

 

[yellow85cj]

If you have been fine without the pins, why replace them with anything?

I am of the belief that they were there more to keep the shaft at a set length during production. Most of the shafts have rusted together long ago and probably wouldn't collapse. And remember the column shaft also collapses.

The "pins" are injection points. The plastic was injected into the shaft at the machined points. Inject the plastic and it fills the machined spot and tightens up the shaft.
https://goo.gl/photos/TDcRrW3RQM2TejMq9

And on this one, apparently the tolerances where a little more than was expected. You can see where the plastic spread a bit.
https://goo.gl/photos/HbNa6DmE583Rt9Wb9

Later models didn't use the injected plastic/nylon(YJ's). The used two flat springs.

https://goo.gl/photos/XMMR4jmpUcoczKGQ9

If you do have concerns or the shaft slides too easily, maybe look for a flat spring (the short one) and use those instead of the pins/screws/whatever.

That's my 2 cents on this one.

 

[81CJ7WY]

I've not replaced the nylon, they drill out very easily however like cheap plastic. So I would think as an opinion, that anything in there plastic like would work. Warm JB weld would work and fill the void as an injection Method if you go that route.

The coupler: do you really want to replace one of the many weakest links in the CJ ? you will find that any steering slop issue comes back to the culprit, the coupler! Then ball joints, and other pivot points.

You gonna lift your Jeep? Any steering slop is augmented by a lift. Friends don't let friends reinstall a steering coupler. in my opinion, a steering shaft upgrade is one of the top mods to do to improve handling. After I did, I kicked myself for putting up with the coupler system for as long as I did.