This van had a knock in the steering column at 11000 miles. Dealer replaced intermediate steering shaft coupler and it went away. At about 25-27000 miles started again. Dealer looked at it and said they could find nothing. Progressively got worse. Had a second opinion (former Ford mechanic now running his own shop). His thought was play in steering wheel, kinda brushed it and me off. Was out no money but no help either.
Been getting worse and at 37000 miles. Happens over slow speed bumps (straight or turning) and going in to hard turns with speed. Going down bumpy road knocks like crazy.
Called well respected front end shop all mechanics around this part of state and even some dealers turn to when they can't find a fix. He stated over phone he was pretty certain it was in steering column issue fixed before based on my description and history. He hadn't seen it in Fords but lotta Chevies and GMC's had problem with no fix just a column that continually wears out.
I've been under hood and dash. Can't find a thing myself but I can get it to duplicate sitting still is to grab upper U-joint ( intermediate shaft coupler) closest at steering column. I grab at this point and it has play and makes it's noise there.

Any ideas or will I have to keep replacing columns parts every 10-15000 miles?

No recalls. Of course calling Ford, they have no history of them looking at it..... and bumper to bumper warranty is gone.

PS,
Also notice grease running out of this Intermediate shaft coupler/ U-joint. Normal? Do these require maintenance? Greasing?
I found a replacement by Dorman. Says they re-engineered these over OEM to eliminate clunking and binding. Any experience? I will say it looks a little different than mine.
http://www.dormanproducts.com/p-2741...n=Intermediate
Thanks.

 

I've almost never heard of that U-joint failing as you describe however that's not saying it doesn't happen. Obviously you've experienced it--twice it seems.

I don't believe there is any sort of PM to be done since its an inside piece. If there are grease Zerks then I'm incorrect but your link doesn't show them present.

Its not common for any part to wear out at 10-15K miles so perhaps the replacement joint was from the same defective batch as the original? They seem to be available from Amazon for about $80.

 

I have ordered one, so lets see what happens.....

 

Please do update us as this proceeds-----could be helpful should someone else encounter the same thing.

Curious myself if you'll drop the entire column or can this be done in place? I'm soon to lower my column to replace/tighten a few things like shift tube bushings. Not yet tackled this in a van though.........

 

It looks like it can be done in place. I have heard only of this part going bad in Tahoe's/Suburbans and a few F150's having a knocking similar to mine, but usually a front rack replacement fixes it.

 

Easy swap out. Just had to loosen two bolts on U-joint to remove it. Shaft collapses.
Got the Dorman after market one. All is well. The Dorman looks a little different and is slightly heavier but I see little dimensional differences and it incorporates a similar ball joint inside.
Without even driving, turning in parked position revealed tighter steering.
Upon driving no more issues, tighter, no knocking.

 

Good deal then----glad it wasn't any more complex or involved!

Nice to have something annoying fixed---gives time to move onto things we ought maybe leave alone huh?

Thanks for the update.

 

Hopefully it will last more than 10-20k!

 

Here we go again......less than 2000 miles and already started knocking. And nobody has a clue. The ding dongs in service at Aiken's and Covington Ford act indifferent.

I haven't had a Ford in a long while last being an 82 Ford F100 along with a 97 Ford E350 Powerstroke. I really got good service out of those. I have to say this van hasn't impressed me much nor Ford in general, nor Aiken's in Winder nor Covington Ford. Other than the transmission going out at 230k and having a mediocre suspension I really miss my Chevrolet Van.