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I have a 78 F250, mine didn't have a rag joint to begin with, it had two U-joints. I believe the instructions have you file or grind a small notch into the spline so you can have a place for the bolt to catch. Its just for added safety. I did do it to mine, with a grinder, I don't want that coming off while driving. You can also spray some paint on the shaft if you want so it does not get all rusty.
Your trying to make it look like the notch in this shaft kinda, except you don't need to go all the way around the shaft. Just one area for the bolt to catch on.
I cut mine so it would be flush like your saying. It doesn't have to be perfect if you leave it an inch or so long you can adjust it however you need and still have it collapse a good amount if needed or make multiple short cuts until you get the fit you desire. I won't be around my truck for a few weeks so I can't take a picture or measurements.
1. Collapse it all the way
2. Can you install it (meaning do you have to extend it a bit to install)? If no keep reading....
3. If it it to long to begin with, measure the distance in between the steering wheel spline shaft and the steering box shaft. Save for later.
4. Install one end to see where it will be, make sure its seated with the lock cross bolt.
5. Mark exposed part of shaft, with masking tape, paint marker..... do to other end.
Remeasure, lay the steering shafts out like installed with the inner and outer pieces beside each other. Adjust to match measurements.
Remeasure everything again, then cut the inner shaft, reassembly, compress together, put in place to install , extend, attach, drink beer.
It its still to long you will have to cut some off the outer tube. I do not think there is any specified amount you have to have inside the tube, leave enough in case you ever install a body lift???
Remember if you cut it too short, or have a drastic steering box change and do not have enough, game over. Cut it long!
I think I have it about at the right length. I will have to pull out the telescoping shaft just a little bit but other than that it looks like it is going to work. I just got to get the aggervating thing on the steering column shaft. Looks like there was an old place where the bolt off the steering column shaft went but I don't know if I will be able to use it and I can't hardly reach back there to do anything.
That stupid bushing off the steering column keeps falling out since the part of the plastic piece that snaps in broke....
Well I finally got the shaft on....steering still feels loose. It steers better but I don't know if the steering gear box needs to be adjusted or not. I don't know if that bushing being not in place is also causing it to act weird...the column outer bearing is right behind it.
On my steering shaft; the bottom u-joint piece I got flushed and I screwed the allen bolt into the dip on the steering gear shaft. Then up on my steering column (it's not really flushed how they said to do it but its about half a centimeter from being flushed) I got the U-joint allen bolt tighten on the filed down place that was already on the steering column.
I hope it wil be ok. I'm thinking about just carrying it to the mechanics and let them looks at it and see what they think.
Tie rod ends good? Than maybe a little adj in the box? Sound like you got it correct, but nothing wrong with a second set of "eyes on", when it comes to steering components.
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