Forgive my lack of using the "search" function, as for some reason I can't use it.

Has anyone replaced their intermediate shaft yet? If so, what were the symtoms you saw in the failed unit?

I still have a slight knock from side to side when rotating the steering wheel. I can feel it in the steering wheel. I just did a new rack, inner and out tie rod ends, upper and lower ball joints. The only other thing I can think of is the intermediate shaft.

 

Mine started by getting very stiff, then once greased had play back and forth, i lived with it for over 2 years until I decided to get it replaced when I had the cash.
I did have to grease it up every now and then.

Mine had about 1-2 inchs of play when I got it replaced. Made other people such at driving it haha
Someone on here put boot around it with grease inside, as a grease-boot kinda idea.

Ive thought about finding a split boot and doing the same idea to mine.

 

I replaced mine, what a huge improvement. Bought a generic part off ebay for $60, actually built nicer than the OEM part. Was super stiff for the first week or so of driving, then started to loosen up, now its perfect

 

So, bringing this one back up. I replaced the lower IM shaft. Knock in steering did not change. I read a TSB that mentioned loosening the upper IM shaft, rotating steering wheel back and forth, then tightening shaft. Did this. Knock went away for a whole 60 seconds of driving, then was back. I seem to be hearing the sound in the column, just above the upper IM shaft...under all the crap that covers the bearing. What is interesting is that I have zero binding, resistance. The column ( with lower IM shaft removed ) spins with zero noise. With everything connected, and tightened, knocking is present. Looks like I will be removing the column...

 

I have the exact same issue in my 2006 the steering wheel feels loose and has that knock. Definitely wanna find out what is wrong and keep the girlfriend from complaining about my truck

 

On the intermediate shaft, the universal at the firewall appears to take all the change of angle and depending on what amount of body lift you have on your truck, the angle that that universal is able to service might be maxed out. This can be felt and sometimes heard when turning the wheel, it will cycle from loose to tight to loose to tight..... as you keep turning in the same direction - the loose is normal and the tight is where the universal binds when being at it's maximum angle. The application of grease and a grease boot helps to some degree, but not much.

Your issue might not relate to this, but if it is, you can see it through the drivers side fender well, or from underneath just behind the front tire. Also, check to see if you have any play in any of the steering column/shaft joints - all this works best as a 2 person job, as long as you can trust the person in the truck not to run over you if you're underneath looking

 

No body lift. The only noise while turning is when you rotate the steering wheel back and forth from 11:00 to 1:00. Knock occurs when the steering when passes the 12:00 mark. While in a turn (steeing wheel is stationary) going over small bumps, the knock turns in to knocking. There is zero play from lower IM shaft, brand new Mopar rack, moog outer tie rod ends, moog upper and lower ball joints. There is no binding or any form of resistance.