Cant remove lower coupler on steering shaft for 1991 dodge dakota

Get the VIN number of the vehicle from the lower left-hand corner of the windshield. Contact the local Dodge dealer with the VIN number. Be prepared to show proof of ownership of the vehicle (title, registration, bill-of-sale). They can cut a replacement key for you.

Sorry no pictures
Replacing the Front Heater Core in a 2006 Dodge Caravan.
1 Turn the steering wheel so that the wheels point straight forward.
2 Disconnect the negative (black) battery cable.
3 Drain the coolant by twisting open the valve at the bottom of the radiator. Use a clean container that holds at least 10.5 quarts. You will reuse the coolant later.
4 Remove the panel on the lower left side of the steering column and disconnect the parking brake cable with a pair of pliers.
5 Unscrew the 10 bolts that connect the steering column cover liner to the instrument panel and remove the cover.
6 Turn the key to the LOCK position and turn the steering wheel to the LOCKED position.
7 Unhook the gear shift cable and remove its mounting bracket.
8 Unscrew the two screws that connect the bezel to the instrument panel and remove the retaining clips. Remove the bezel.
9 Remove the two screws that connect the steering column shroud to the column and remove the shroud.
10 Remove the coupler from the steering column and intermediate steering shaft.
11 Loosen the nuts that connect the lower steering column mounting bracket, but do not remove them. Completely remove the two nuts and washers from the upper bracket.
12 Pull out the steering column.
13 Remove the interconnect and bracket that connects the instrument panel to the chassis wiring.
14 Remove the boot from the bottom of the steering shaft.
15 Use locking pliers to pinch off the heater hoses in the engine compartment. Remove the plate covering the heater core (the hoses run through it) and disconnect the hoses.
16 Unclip the connectors that hold in the heater core. Lift the accelerator pedal to enable you to slide the heater core out part way. Press the brake pedal to make room to completely remove the heater core.
17 Replace the heater core. Installation is the reverse of removal. The nuts on the steering column mounting bracket should be torqued to 105 ft. lbs. Torque the pinch bolt on the coupler to 21 ft. lbs.

The 2001 Dodge caravan has 2 heater cores - front (the main one), and the rear. Removal of the
rear heater core is a whole different procedure than the front.

Front Heater Core - Removal and Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. Align the wheels in the straight-ahead position.
3. Disconnect the negative battery cable.
   CAUTION Before working around the steering wheel or the instrument panel all 2 minutes to pass to allow the air bag module to discharge.
   
4. Drain the cooling system into a clean container for reuse.
5. Remove the steering column, by removing or disconnect the following:
   
   Lower left side steering column cover Parking brake release cable from the parking brake lever 10 steering column cover liner-to-instrument panel bolts and the cover liner
6. Rotate the key to the LOCK position; then, rotate the steering wheel to the LOCKED position.
   
   Gear selector cable and its mounting bracket as an assembly from the upper steering column mounting bracket 2 instrument cluster trim bezel-to-instrument panel screws, retaining clips and bezel 2 steering column shroud-to-steering column screws and the shroud Steering column-to-intermediate steering shaft coupler
   
7. Loosen but do not remove the 2 lower steering column mounting bracket nuts/washers.
   
   2 upper steering column mounting bracket nuts/washers Steering column assembly from the vehicle
   
8. Remove or disconnect the following:
   
   Instrument panel-to-chassis harness interconnect and bracket Lower silencer boot, at the base of the steering shaft
   
9. Working in the engine compartment, pinch off the heater hoses.
   
   Heater core cover. Position some towels under the heater core hoses. Heater core plate and the hoses
   
10. Depress the heater core retaining clips.
11. Lift the accelerator pedal and slide the heater core past it.
12. Depress the brake pedal and remove the heater core from the heater/air conditioning housing assembly.
    
    

    Fig. View of the steering column assembly
    
    
    

    Fig. View of the interconnect and bracket
    
    
    

    Fig. View of the front heater core assembly
    

To install:

1. Depress the brake pedal and install the heater core into the heater/air conditioning housing assembly.
2. Lift the accelerator pedal and slide the heater core past it.
3. Install or connect the following:
   
   Heater hoses (using new O-rings) and the heater core plate Heater core cover Heater hoses clamps, working in the engine compartment Lower silencer boot at the base of the steering shaft Instrument panel-to-chassis harness interconnect and bracket
   
4. Install the steering column assembly by installing or connect the following:
   
   Steering column assembly, carefully into the vehicle. 2 upper and 2 lower steering column mounting bracket nuts/washers. Torque the nuts to 105 inch lbs. (12 Nm). Steering column-to-intermediate steering shaft coupler and tighten the pinch bolt to 21 ft. lbs. (28 Nm) 2 steering column shroud and the shroud-to-steering column screws Bezel, the retaining clips and the 2 instrument cluster trim bezel-to-instrument panel screws Gear selector cable and its mounting bracket as an assembly to the upper steering column mounting bracket 10 steering column cover liner and the cover liner-to-instrument panel bolts Parking brake release cable to the parking brake lever Lower left side steering column cover. Lower left side steering column cover
   
5. Refill the cooling system.
6. Connect the negative battery cable.
7. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Remove the outer tie rods from the knuckles. Turn the knuckles by hand. If they turn hard than you have issues with ball joints binding.

If they move freely than start the vehicle and turn the wheel. If you steering is still stiff I would be suspicious of the universal joint near the rack. If you remove it it should rotate and flex freely. If it doesn't replace it.

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1997 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable. Disarm the air bag system.
3. Remove or disconnect the following:
4. Transaxle gearshift cable from the shifter lever
5. Loosen the gearshift cable-to-transaxle mount bolt
6. Gearshift cable from the transaxle
7. Throttle cable from the throttle body, if necessary
8. Throttle cable bracket
9. Both wiper arm assemblies from the wiper arm pivots
10. Cowl closure panel and weather-stripping as an assembly from the cowl
11. Wiper module wiring harness from the vehicle wiring harness
12. Wiper module assembly from the cowl panel
13. Air plenum from the throttle body, PCV make up air tube and the idle air control motor. Remove the plenum from the right side of the vehicle through the wiper module area.
14. Power brake booster vacuum connector at the intake manifold
15. Turn the front wheels to the full left position. Then, turn the wheels back in the other direction until the roll pin in the lower steering coupler is accessible. Turn the ignition key switch to the LOCK position to keep the steering column from rotating after the coupler is removed from the steering gear. If the steering column shaft rotates beyond the normal number of turns in either direction, the air bag clock spring will be damaged. Fig. 1: Matchmark the steering coupler to the intermediate shaft for proper alignment
    Fig. 2: Steering rack-to-subframe attaching bolt locations — replace mounts if worn
    
    
16. Using paint, mark the steering coupling and steering gear shaft for orientation. Using the correct size punch, remove the roll pin from the steering coupling.
17. If equipped, remove the pedal travel sensor from the brake booster as follows:
    1. Pump the brake pedal approximately 20 times. This will bleed the vacuum stored in the booster.
    2. Remove the wiring harness connector from the sensor.
    3. Using a small flat-tipped tool, lift the retainer ring from the notch. Then, remove the retaining ring from the grommet.
    4. Remove the pedal travel sensor from the brake booster by carefully pulling it straight out of its mounting grommet. Do not twist the sensor.
18. Remove or disconnect the following:
19. Master cylinder from brake booster with the brake lines connected and position aside
20. Power steering pressure hose and return hose from the power steering gear
21. Bend back the tie rods-to-steering gear bolt retaining tabs and remove the bolts
22. Lay the tie rods, bolts and plate as an assembly on the bell housing of the transaxle.
23. If the rack and pinion steering gear unit being removed is a speed proportional steering gear, disconnect the vehicle wiring harness from the solenoid control module.
24. Remove or disconnect the following:
25. 4 bolts attaching the steering gear assembly to the crossmember. Slide the steering gear forward in the vehicle to disengage the steering coupler from the steering gear shaft. After the gear is disengaged, do not rotate the steering gear shaft
26. Steering gear assembly from the vehicle through the area in the cowl from which the windshield wiper module was previously removed To install:
    
27. If a replacement rack is being installed, grasp the shaft of the steering gear and rotate it until the steering gear center take off is in a full left turn position. Install the steering gear into the vehicle through the wiper module opening in the cowl.
28. If the original gear is being installed, align the paint mark on the steering coupler with the mark on the steering gear shaft and install the steering gear shaft into the steering gear coupler.
29. If a replacement rack is being installed, the steering gear shaft and steering coupler must be aligned. Rotate the steering gear shaft back from the full left turn position until the master spline on the steering gear shaft is aligned with the master spline on the steering coupler. At this point, install the steering gear into the coupler.
30. Align the steering gear with the mounting holes in the crossmember and install the bolts. Be sure the brake line routing clip is installed under the left steering gear mounting bracket. Tighten the mounting bolts to 50 ft. lbs. (68 Nm).

Likely, you could leave it right there and work around it but if you want it out, there should be a coupler on the shaft to remove the top half. Don't know which coupler style you have but most have either a through bolt retainer or a roll pin that is driven out. If the coupler is under the dash, column will then come out, if on firewall side you may need to remove the cover bolts on the firewall.

no there is not enough room to get it past the crossmember you may have to lower the front diff also if it is 4wd

Hello
Welcome to FixYa
there is a u joint to be replaced on your steering shaft just after the steering shaft
open the hood look down to the steering shaft you will see a small u joint very common to go bad most auto parts stores carry the part
RD

jj, here's the procedure:
turn ignition key to locked position and turn steering wheel to the left until the wheel is locked. Remove key.
While vehicle still on ground disconnect the steering column shaft coupler from the steering gear intermediate coupler. Remove the cotter key the nut and the pinch bolt.
Loosen wheel lug, raise vehicle support securely w/ jack stands, remove the wheels.
Raise the insulating wrap on the power steering return hose to expose the hose clamp. Remove the hose clamp and detach the hose, Drain ps fluid thru the hose.
Remove both tie rod ends from steering knuckles.
Remove the 2 bolts and loosen the 3rd attaching the anti-lock brakes Hydraulic control Unit (HCU) to the suspension cradle.
then rotate the HCU rearward to allow access to the cradle bolt and nut just forward of the hcu.
Remove the nuts and bolts attaching the cradle plate to the bottom of the front suspension cradle, then remove cradle plate from cradle.
Remove bracket attaching power steering fluid line to the front suspension cradle.
Detach ps.fluid pressure and return lines from the ps gear.
Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle.
Lower the steering gear from the suspension cradle enough to allow access to the intermediate coupler roll pin. Install a roll pin remover/installer tool (they always get u with that darn special tool, don't they?) or equivalent set up. Pull the roll pin out of the intermediate coupler. Separate the intermediate coupler from the shaft of the steering gear Remove the steering gear assembly from the suspension cradle. Well, it's too late to give the install procedure, but u seem to have it under control, so let me know if u need more info and how u make out! Merry Christmas!