Disassembly and Reassembly

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. Remove No.2 lower cover.
Remove the 2 nuts.





2. Remove intermediate shaft assembly.
a. Place matchmarks on the shaft assembly and main shaft assembly. Remove the bolt.
c. Remove the thrust stopper.
3. Remove No.2 lower cover.
4. Remove transponder key coil with key cylinder lamp assembly.
Remove the screw.
5. Remove key cylinder lamp assembly.
Remove the lamp assembly from the key coil.
6. Remove connector bracket.
Remove the bolt.
7. Remove steering column protector No.1
Remove the bolt.
8. Remove turn signal bracket.
Remove the 3 bolts.
9. Remove power tilt motor.
a. Using a hexagon wrench, remove the support stopper bolt.
b. Remove the stopper spring and stopper No.1.
c. Using a hexagon wrench, remove the 2 tilt steering bolts.
d. Using a screwdriver, remove the 2 E-rings.
e. Remove the 2 support stopper bolt bushings from the motor.





10. Remove adjusting nut No.1.
a. Set Special Service Tool (SST) 0991-00015 (09911-00011, 09912-00010) or equivalent, a plate washer (36 mm outer diameter) and bolt (10 mm normal diameter, 1.25 mm pitch, 50 mm length), as shown.
Reference:
- Plate washer 90201-10201
- Bolt 91111-51050
b. Remove the 2 tilt steering shafts by using the sliding hammer on SST.
c. Remove the 2 support stopper bolt bushings from the adjusting nut No.1.
11. Remove power telescopic motor.
a. Remove the 2 bolts.
b. Remove the telescopic steering column cable.





12. Remove column upper bracket and column upper clamp.
a. Using a centering punch, mark the center of the 2 tapered-head bolts.
b. Using a 3-4mm (0.12-0.16 inch) drill, drill into the 2 bolts.
c. Using a screw extractor, remove the 2 bolts.
d. Using a hexagon wrench, remove the 2 telescopic lever lock bolts.
e. Remove the 2 telescopic steering wedge lock springs and 2 steering lock wedges.
13. Remove column tube support.
a. Remove the bolt.
b. Remove the tube support with lower tube attachment.
c. Remove the tube attachment from the tube support.





14. Remove 2 energy absorbing plates.
a. Using pliers, remove the energy absorbing clip.
b. Remove the energy absorbing plate and energy absorbing guide.
15. Remove telescopic steering slider support.
Remove the 2 bolts.
16. Remove telescopic steering bushing.
17. Remove telescopic steering slider.
18. Remove telescopic steering screw.
Remove the nut, 4 energy absorber cushions, 2 bearings and steering screw.
19. Remove column upper tube sub-assembly with main shaft assembly.
a. Using a screwdriver, remove the snap ring.
b. Using a hexagon wrench, remove the 2 tilt steering bolts.
c. Remove the column upper tube assembly from the column tube.
d. Remove the 2 support stopper bolt bushing from the column upper tube assembly.
e. Remove the 3 bushings from the column tube.





20. Remove main shaft assembly.
a. Using SST 09950-00011 (09958-04010), compress the compression spring.

NOTICE: Do not bend the universal joint of the shaft assembly more than 20°.

b. Using a snap ring expander, remove the snap ring.
c. Remove the shaft assembly from the column upper tube.
d. Remove the compression spring and bearing thrust collar from the shaft assembly.



INSPECTION

NOTICE: When using a vise, do not overtighten it.






1. Inspect steering lock operation.
Check that the steering lock mechanism operates properly.





2. If necessary, replace key cylinder.
a. Place the ignition key at the ACC position.
b. Using a screwdriver, push down the stop pin of the cylinder, and pull out the key cylinder.
c. Install a new cylinder.

HINT: Make sure the key is at the ACC position.

3. Inspect ignition switch.
4. If necessary, replace ignition switch.
a. Remove the 2 screws.
b. Install a new switch with the 2 screws.
5. Inspect key unlock warning switch.
6. If necessary, replace key unlock warning switch.
a. Slide out the switch.
b. Slide in a new switch.
7. Inspect key interlock solenoid.
8. If necessary, replace key interlock solenoid.
a. Remove the 2 screws.
b. Install a new solenoid with the 2 screws.
9. Inspect transponder key coil.
10. If necessary, replace transponder key coil.
11. If necessary, replace transponder key amplifier.
a. Remove the 2 screws.
b. Install a new key amplifier with the 2 screws.





12. Inspect bearing.
a. Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the column upper tube.
b. Coat the bearing with molybdenum disulfide lithium base grease.





13. Inspect bearing
a. Check the bearing rotation condition of the main shaft assembly and check for abnormal noise.
If necessary, replace bearing.
b. Coat the bearing with molybdenum disulfide lithium base grease.



REASSEMBLY

NOTICE: When using a vise, do not over tighten it.

1. Coat with molybdenum disulfide lithium base grease.





2. Install main shaft assembly.
a. Install the bearing thrust collar and compression spring to the shaft.
b. Install the shaft assembly to the column upper tube.
c. Using SST 0995-40011 (09958 04010), compress the compression spring.

NOTICE: Do not bend the universal joint of the shaft more than 20°.

d. Using a snap ring expander, install a new snap ring to the shaft.
3. Install column upper tube sub-assembly with main shaft assembly.
a. Install the 3 bushings to the column tube.
b. Install 2 new support stopper bolt bushings to the column tube assembly. Install the column upper tube assembly to the column tube.
d. Using a hexagon wrench, install the 2 tilt steering bolts.
Torque: 20 Nm (15 ft. lbs.)
e. Install a new snap ring.
4. Install telescopic steering screw.
a. Install the 4 energy absorber cushions, 2 bearings and steering screw.
b. Torque the nut.
Torque: 2 Nm (17 inch lbs.)
5. Install telescopic steering slider.
6. Install telescopic steering bushing.
7. Install telescopic steering slider support.
Tighten the 2 bolts.





8. Install 2 energy absorbing plates.
a. Install the new energy absorbing guide and new absorbing plate.
b. Install the new energy absorbing clip.
9. Install column tube support.
a. Install the attachment to the tube support.
b. Torque the bolt.
Torque: 15 Nm (11 ft. lbs.)





10. Install column upper bracket and column upper clamp.
a. Install the 2 telescopic steering wedge lock springs and 2 steering lock wedges.
b. Using a hexagon wrench, install the 2 telescopic lever lock bolts.
Torque: 10 Nm (7 ft. lbs.)
c. Tighten the 2 new tapered-head bolts until the bolt heads break off.
11. Install power telescopic motor.
a. Install the telescopic steering column cable.
b. Torque the 2 bolts.
Torque: 9 Nm (78 inch lbs.)
12. Install adjusting nut No.1.
a. Install 2 new support stopper bolt bushings.
b. Install the 2 tilt steering shafts.
13. Install power tilt motor.
a. Install 2 new support stopper bolt bushings to the motor.
b. Install 2 new E-rings.
c. Using a hexagon wrench, install the 2 tilt steering bolts.
Torque: 20 Nm (15 ft. lbs.)
d. Install the support No.1 and support spring.
e. Using a hexagon wrench, install the support stopper bolt.
14. Install turn signal bracket.
Tighten the 3 bolts.
15. Install steering column protector No.1.
Torque the bolt.
Torque: 15 Nm (11 ft. lbs.)
16. Install connector bracket.
Tighten the bolt.
17. Install key cylinder lamp assembly.
Install the lamp assembly to the key coil.
18. Install transponder key coil with key cylinder lamp assembly.
Tighten the screw.
19. Install No.2 lower cover.
20. Install intermediate shaft assembly.
a. Install the thrust stopper.
b. Align the matchmarks on the shaft assembly and mainshaft assembly.
c. Torque the bolt.
Torque: 34 Nm (25 ft. lbs.)
21. Install No.2 lower cover.
Torque the 2 nuts.
Torque: 24.5 Nm (17 ft. lbs.)