Disassembly and Reassembly

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY

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

1. Remove ignition key cylinder illumination with transponder key coil.
a. Disconnect the connector.
b. Remove the screw.





2. Remove No. 2 intermediate shaft assembly.
a. Place matchmarks on the main shaft and No. 2 intermediate shaft.
b. Remove the bolt.
3. Remove telescopic sensor plate. Remove the bolt.
4. Remove telescopic position sensor.
a. Disconnect the connector.
b. Remove the 2 screws.
5. Remove tilt position sensor.
a. Remove the wiring harness clamp.
b. Remove the screw.
6. Remove turn signal bracket. Remove the 3 bolts.
7. Remove protector and No. 2 protector. Remove the 3 bolts and screw.
8. Remove connector bracket. Remove the 2 bolts.
9. Remove column upper bracket.
a. Using a centering punch, mark the center of the 2 tapered head bolts.
b. Using a 4 - 5 mm (0.16 - 0.20 inch) drill, drill into the 2 bolts.





c. Using a screw extractor, remove the 2 bolts.





10. Remove tilt steering gear assembly with motor.
a. Remove the 2 adjusting nuts, springs and plate washer.
b. Remove the bond cable with screw.
c. Set SST 09213 - 54015 (09214 - 00030), 09910-00015 (09911 -00011, 09912-00010), or equivalents, and 2 plate washers (18 and 36 mm outer diameter), as shown. And then remove the 2 No. 2 tilt steering shafts. Reference:
Plate washer A: 90562 - 04012
Plate washer B: 90201 - 10201
d. Remove the 2 bushings from the tilt steering gear assembly with motor.
e. Remove the 2 support stopper bolts with set bolts.





11. Remove column upper tube with main shaft and No. 1 main shaft.
a. Set SST 09213 - 54015 (09214 - 00030), 09910 - 00015 (09911 - 00011, 09912 - 00010), or equivalents, and 2 plate washers (18 and 36 mm outer diameter), as shown. And then remove the 2 tilt steering shafts. Reference:
Plate washer (A): 90562 - 04012
Plate washer (B): 90201 - 10201
b. Using a snap ring expander, remove the snap ring from the No. 1 main shaft.
c. Remove the upper tube with main shaft and No. 1 main shaft.
d. Remove the No. 1 main shaft.
e. Using a snap ring expander, remove the snap fir from the No. 1 main shaft.





12. Remove main shaft.
a. Using SST 09950 - 40010 (09958 - 04010), compress the compression spring.

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

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





13. Remove radial ball bearing.
a. Using snap ring pliers, remove the snap ring from the breakaway bracket with telescopic motor.
b. Using SST 09950 - 60010 (09951 - 00280), 09950-70010 (09951-07200), and hammer, drive out the ball bearing.

14. Remove tilt steering housing support. Remove the 4 bolts.
15. Remove column tube support.
a. Remove the bolt.
b. Remove the clip from the support.
16. Remove No. 1 lower tube bracket. Remove the bolt.





17. Remove 2 energy absorbing plates. Using a pin punch and hammer, tap out the energy absorbing pin. Remove the plate roller. plate and guide.

INSPECTION AND SERVICE

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. Push down the stop pin with a screwdriver, and pull out the cylinder.
c. Install a new cylinder.

HINT: Make sure the ignition key is at the ACC position. Do not operate steering lock with the cylinder removed.

3. Inspect ignition switch.
4. If necessary, replace ignition switch.
a. Remove the 2 screws.
b. Install new switches with the 2 screws.
5. Inspect key unlock warning switch.
6. Inspect key interlock solenoid.
7. if necessary, replace key interlock solenoid with key unlock warning switch.
a. Remove the 4 screws.
b. Install a new solenoid and warning switch with the 4 screws.
8. Inspect transponder key coil.
9. If necessary, replace transponder key coil.
a. Remove the key coil from the ignition key cylinder illumination.
b. Install a new key coil to the ignition key cylinder illumination.





10. If necessary, replace transponder key amplifier.
a. Remove the 2 screw.
b. Install a new key amplifier with the 2 screws.
11. Inspect bearing. Check the bearing rotation condition and check for abnormal noise. If it is faulty, replace the column upper tube.
12. If necessary, adjust 2 telescopic adjusting screws.
a. Using SST 09922 - 10010, remove the lock nut.





NOTICE: Use SST 09922 - 10010 in the direction shown.





b. Using a 17 mm hexagon wrench, torque the adjusting screw to 7 Nm (62 inch lbs.).





NOTICE:
^ If the adjusting screw is tightened higher than the specified torque, the telescopic mechanism may malfunction. Conversely, if the torque applied is ton low, rattling may develop in the column, so the specified torque should always be applied.
^ When the adjusting screw and conical springs have been removed. replace the conical springs facing in the direction shown in the illustration.





c. Using a 17 mm hexagon wrench to hold the adjusting screw and using SST 09922 - 100 1 0, torque the lock nut to 26 Nm (19 ft. lbs.)

NOTICE: Use SST 09922 - 10010 in the direction shown in the illustration.

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

ASSEMBLY

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

1. Coat with molybdenum disulfide lithium base grease.
2. Install 2 energy absorbing plates. Install the energy absorbing roller, pin, guide and plate.
3. Install No. 1 lower tube bracket.
Torque the bolt to 2.8 Nm (25 inch lbs.)
4. Install column tube support.

NOTICE: If the clip or support is deformed, replace it with a new one.





a. Install the clip to the support until its stopper contacts the support.
b. Install the support.

NOTICE: Make sure you install the support facing the correct direction.
c. Torque the bolt to 15 Nm (11 ft. lbs.)

NOTICE: Tighten the bolt while holding the support to prevent it turning too. Be sure to tighten the bolt to the specified torque.

5. Install tilt steering housing support. Torque the 4 bolts to 13 Nm (9 ft. lbs.)
6. Install radial ball bearing.
a. Coat a new ball bearing with molybdenum disulfide lithium base grease.





b. Using SST 09950 - 60010 (09951 - 00190, 09951 - 00340, 09952 - 06010), 09950 - 70010 (09951 - 07100), press in the ball bearing. Using snap ring pliers, install a new snap ring to the breakaway bracket with telescopic motor.
7. Install main shaft.
a. Coat a new bearing with molybdenum disulfide lithium base grease.
b. Install the bearing, thrust collar and compression spring to the main shaft.
c. Install the main shaft into the column upper tube.





d. Using SST 09950 - 40010 (09958 - 04010), compress the spring.

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

e. Using a snap ring expander, install a new snap ring.





8. Install No. 1 main shaft.
a. Align the ditch of the No. 1 main shaft and projection of the main shaft, and install the No. 1 main shaft in the main shaft.
b. Using a snap ring expander, install a new snap ring to the No. 1 main shaft.
9. Install tilt steering gear assembly with motor.
a. Install the 2 bushing to the tilt steering gear assembly with motor.
b. Install the 2 support stopper bolts with 2 bolts and torque to 5 Nm (44 inch lbs.)





c. Using a vise, press in the 2 No. 2 tilt steering shaft.
d. Install a new plate washer, springs to each adjusting nuts.
e. Install the bond cable.
f. Torque new lock nuts and torque to 3 Nm (27 inch lbs.)
g. Tighten the bond cable set screw.
10. Install column upper tube with main shaft and No. 1 main shaft.
a. Install the column upper tube with main shaft and No. 1 main shaft.
b. Using a snap ring expander, install a new snap ring to the No.1 main shaft.





c. Using a vise, press in the 2 tilt steering shafts.

HINT: Make sure the upper tube turns smoothly.





11. Install column upper bracket. Tighten the 2 new tapered head bolts until the bolt heads break off.
12. Install connector bracket. Torque the 2 bolts to 2.8 Nm (25 inch lbs.).
13. Install protector and No. 2 protector.
a. Torque the 3 bolts to 5 Nm (44 inch lbs.).
b. Tighten the screw.
14. Install turn signal bracket and torque the 3 bolts to 5 Nm (44 inch lbs.).
15. Install tilt position sensor.
a. Tighten the screw.
b. Install the wiring harness clamp.
16. Install telescopic position sensor.
a. Tighten the 2 screws.
b. Connect the connector.





17. Install telescopic sensor plate.
a. Install the sensor plate, as shown in the illustration.
b. Torque the bolt to 5 Nm (44 inch lbs.)
18. install ignition key cylinder illumination with transponder key coil.
a. Install the screw.
b. Connect the connector.
19. Install No. 2 intermediate shaft assembly.
a. Align the matchmarks on the main shaft and No. 2 intermediate shaft.
b. Torque the bolt to 35 Nm (26 ft. lbs.)