We're working on my son's 1986 Ram 150 van. We're replacing the lower column coupler (Haynes Manual term) and the steering gear. We've got the old ones out and trying to put the new ones in, but I can't seem to get the splines to mate. There is one wider spline or key in there that we have to line up but it still son't go on. I am tempted to heat up the coupling so that it may slide onto the steering gear easier. The "books" just say to slide it on. We've tried to also put the new coupling onto the old steering gear, and even tried to put the old coupling back onto the old steering gear, but none seem to be able to slide on. I'm looking for some sort of magic "pro trick" or some advice on what to try next. I think this is the same coupling and steering box that I had on my old (long gone)Volare so I don't think it is just a van issue. Any help would be appreciated. Thanks

 

It's a very precise fit. You need to have the splines lined up perfectly and the shaft needs to be straight into the coupling. A good dousing of WD-40 tends to help it slide ina lot.

 

Thanks alot. I did soak the heck out of it and, rightly or wrongly, tapped it on with a mallet so it seems fine now. Thanks again.