Hello everyone, A few weeks ago I replaced several steering components on my 2006 Ford Expedition, including the steering rack, lower steering shaft, inner and outer tie rod ends, and some power steering fluid lines. After the repair, I took the truck for a wheel alignment and everything felt perfect for the first few days. However, after about 200 miles, the steering gradually became looser and started developing a clunky feel. Today I also noticed that the steering wheel is now about 10 degrees off-center — I have to hold it slightly to the right in order to drive straight. An annoying clicking noise has also appeared.

I inspected the steering system and found that the upper U-joint on the lower steering shaft is completely loose. The four 13mm bolts/nuts that secure the rubber bushing assembly had backed off, and there is also noticeable play at the pinch-bolt connection between the upper and lower steering shaft sections. I re-torqued the four bolts, which helped, but I still cannot eliminate the play at the clamp connection between the shafts. The 13mm pinch bolt is already very tight — tight enough that I can’t realistically torque it any further by hand. What confuses me is that everything was tight immediately after installation, so I’m not sure what caused it to loosen up so quickly.

At this point I’m trying to figure out the best way to deal with the remaining play in the clamp connection. Could this simply be poor machining/tolerance on the aftermarket steering shaft? Or should I try tightening the pinch bolt further with a breaker bar/leverage?

https://i.imgur.com/845n5cy.jpeg

 

Yes, it is the aftermarket lower shaft
You couldn't find a Ford one?
Chicken sheet repair, but I used to take cardboard and cram it into the rag joint connection to the rack on 1991-1995 Taurus
I did that to about a hundred shafts back in the mid 90's
Tightened them right up
Course, that was a Ford factory shaft that was machined a bit loose
You may not be able to fix yours if it's pot metal

 

You’re right — it’s an aftermarket steering shaft from a brand called Lares. Unfortunately, I wasn’t able to get an OEM Ford unit because they’ve been discontinued, and I couldn’t find one available through any dealer or parts supplier anymore.

Can anyone recommend a more reputable brand for replacement steering shafts? I’d rather replace it with something higher quality if there’s a better option available.

 

Not sure if you went R-A for part. They are usually good about ensuring decent quality, but I also see they sell that brand you mention. I haven't replaced any steering parts on my '06 F-150 yet, but I haven't had any negative issues with any Dorman brand parts. So far...

 

Me either, maybe clamp it down really tight
Maybe running it loose, the splines got worn out

 

Yes, I do shop on RockAuto. I buy a lot of parts from them because I’m a hobbyist and I work on multiple automotive projects. You mentioned Dorman, but for me that’s a big “no.” I’ve had several bad experiences with their parts — some of them literally fell apart during installation. Maybe I was just unlucky, but after those experiences I honestly don’t want to buy anything from that manufacturer again.

If I can find some time on Saturday, I’ll disassemble the upper clamp and inspect the splines. Honestly, I even considered putting a small spot weld on it — just enough to eliminate the play.

 

Does Borgeson make steering shafts for these? Not cheap, but very good quality.