Aligning the intermediate shaft

[mriggio]

So I'm replacing the steering gear on my 1980 CJ7 and when I removed the previous gear, it took a little motivation to separate the intermediate shaft from the steering gear at the coupling.

Now as I'm replacing the gear with a re-manufactured gear, I can't get the intermediate shaft to slide over the new steering gear. It mates up, is the same diameter as the old gear, and seems to have the same number of teeth, but doesn't slide on.

Any suggestions?

 

[mriplaybass]

Make sure that the splines on both sides are clean and no burrs exist. Orient the coupler so that the bolt aligns with the recess in the gear box shaft. If necessary, slightly pry the connector apart just slightly with a screwdriver. It should slip right on, or maybe just a little light tapping with a small hammer.

 

[mriggio]

Thanks for the advice! Finally got time this weekend to get back under the Jeep and although the new gear had a channel all the way around it (making it appear that the pin could go in anywhere), closer examination showed it still had a definite flat spot. Aligned that and things definitely went better. Since I’m up in PA, it also helped when I dragged out the heat gun and warmed up the coupling. Back on business! Thanks for the advice.

 

[Lumpy Grits]

Coat the splines with copper anti-seize compound.

LG

 

[mriggio]

Good point! As a former ship engineer I never forget the stuff for these types of joints, but definitely a great reminder. Thanks!