Manual Tilt and Telescopic Steering Column

Disassembly

Fig. 16 Exploded View Of Steering Column:

1. Remove ignition key cylinder illumination and sliding yoke, Fig. 16.
2. Remove clip and lower dust cover, then using a screwdriver, remove dust seal.
3. Remove upper bracket as follows:
a. Using a centering punch, mark center of tapered head bolts.

Fig. 17 Upper Bracket Retaining Bolt Removal:

b. Using a 0.16-0.20 inch drill, drill into tapered head bolts, Fig. 17.
c. Using a screw extractor, remove tapered head bolts.
d. Remove two bolts, then separate upper bracket and breakaway bracket.
4. Remove turn signal bracket, protector and connector bracket.
5. Remove nut and telescopic lever serration attachment.
6. Remove telescopic lever bolt, collar, lever and washer, then remove ball and compression spring.
7. Install a double nut on telescopic lever lock bolt, then remove lock bolt.
8. Remove breakaway bracket as follows:
a. Remove steering column tube stopper bolt.
b. Using snap ring pliers, remove snap ring from main shaft.
c. Remove breakaway bracket from main shaft. Ensure spline part of main shaft does not come loose.
9. Remove two lock wedges from breakaway bracket, then remove steering shaft thrust stopper.
10. Using a Torx wrench, remove compression spring bolt, compression spring and bushings.
11. Remove three tension springs.
12. Remove tilt lever retainers as follows:
a. Remove nut and washer, then pull out the bolt.
b. Remove two E-rings and spacers from tilt lever lock shaft.
c. Remove two nuts from tilt steering bolts, then two tilt lever retainers.
d. Remove collar from tilt memory bolt.
13. Remove right hand tilt pawl. pawl stopper and tilt lever.
14. Remove left hand tilt pawl, pawl stopper, tilt sub lever, tilt lever assembly and tilt lever lock shaft.
15. Remove upper column tube as follows:

Fig. 18 Upper Column Tube Removal:

a. Install special service tool No. 09910-00015 or equivalent, nut (part No. 90170-10004), plate washer (part No. 90201-10201) and bolt (part No. 91111-51050) as shown in Fig. 18.
b. Remove two tilt steering bolts.
c. Remove upper column tube from lower column tube.
16. Using a hexagon wrench, remove tilt memory bolt and square nut.
17. Remove main shaft as follows:

Fig. 19 Main Shaft Snap Ring Removal. W/ Manual Tilt & Telescopic:

a. Using special service tool No. 09950-20017 or equivalent, compress main shaft spring, then remove snap ring with snap ring pliers, Fig. 19.
b. Remove main shaft from column tube.
c. Remove spring, thrust collar and bearing.

Assembly

1. Apply molybdenum disulfide lithium base grease to all moving parts during assembly.
2. Install mainshaft as follows:
a. Install bearing, thrust collar and spring to main shaft.
b. Insert main shaft into upper column tube.
c. Using special service tool No. 09950-20017 or equivalent, compress main shaft spring, then install snap ring with snap ring pliers.
3. Install square nut and tilt memory bolt, then torque bolt to 56 in. lb.
4. Select tilt steering bolts as follows:
a. If the upper column tube is marked with a 2, select bolt with plain thread.
b. If the upper column tube is marked with a 1, select bolt with hollow-tipped thread.
5. Install collar to main shaft, then insert main shaft with upper column tube into lower column tube.
6. Using a vise, press in two steering bolts. Ensure upper tube turns smoothly.
7. Install tilt lever lock shaft, tilt lever assembly, tilt sub lever and tilt lever as follows:
a. Insert tilt lever lock shaft into upper column tube.
b. Install tilt lever assembly.
c. Install tilt lever and sub lever.
8. Install tilt pawls as follows:
a. Install two tilt pawls to upper column tube.
b. Install bolt through tilt pawls and tilt lever assembly.
c. Temporarily install washer and nut.
d. Install and torque tilt lever assembly installation bolt to 26 in. lb.
9. Engage and adjust tilt pawl as follows:
a. Engage tilt sub lever side pawl to center of ratchet.
b. While turning tilt lever side collar, completely engage tilt lever side pawl to ratchet.
c. Place matchmarks on pawl and collar, then remove nut and washer and pull out bolt.
10. Select pawl stoppers as follows:
a. With tilt pawl and ratchet engaged, install two pawl stoppers.
b. Ensure alignment marks on stopper and pawl align when stopper is lightly rotated to pawl side.

Fig. 20 Pawl Stopper Identification Chart. W/ Manual Tilt & Telescopic:

c. If alignment marks do not align, select pawl stoppers according to the chart in Fig. 20.
d. After selecting stoppers, ensure both sides of pawl and ratchet are fully engaged.
11. Install pawl stoppers and tilt lever retainers as follows:
a. Install tilt sub lever side pawl stopper and tilt lever retainer.
b. Install spacer and E-ring, then install and torque tilt steering nut and bolt to 11 ft. lb.
c. Install collar and nut to tilt memory bolt. Torque nut to 52 in. lb.
d. Install tilt lever side pawl stopper and tilt lever retainer.
e. Install spacer and E-ring, then install and torque nut to 11 ft. lb.
12. Install tilt pawl bolt and torque to 52 in. lb. with matchmarks on pawl and collar aligned.
13. Install three tension springs.
14. Install compression spring, bushings and bolt. Using a Torx wrench, torque bolt to 69 in. lb.
15. Install two lock wedges to breakaway bracket.
16. Install breakaway bracket as follows:
a. Install steering shaft thrust stopper.
b. Install breakaway bracket to main shaft. Ensure splined part of mainshaft does not separate.
c. Using snap ring pliers, install snap ring to main shaft.
d. Install steering column tube stopper bolt and torque to 14 ft. lb.
17. Install telescopic lever lock bolt as follows:
a. Pull steering column tube away from breakaway bracket, then face body installation surface of breakaway bracket upward and temporarily install lock bolt.
b. Install double nut on lock bolt.
c. Torque lock bolt to 12 ft. lb., then loosen and retorque to 65 in. lb.
18. Install telescopic lever as follows:
a. Install compression spring and ball.
b. Install washer, lever, collar and bolt. Torque bolt to 19 ft. lb.
19. Rotate telescopic lever until it touches breakaway bracket.
20. Install serration attachment so alignment marks on telescopic lever and serration attachment align. Install nut and torque to 9 ft. lb.
21. Install connector bracket. Torque bolts to 43 in. lb., then install protector.
22. Install turn signal bracket with its upper surface parallel with upper surface of capsule of breakaway bracket.
23. Install upper bracket with two new tapered-head bolts, then tighten bolt until bolt heads break off.
24. Using a press, install dust seal, then install lower dust cover and clip.
25. Install sliding yoke and torque bolt to 26 ft. lb.
26. Install ignition key cylinder illumination.
27. Check tilt operation as follows:
a. Ensure there is no axial play at end of main shaft.
b. With main shaft in neutral position, push tilt lever and ensure main shaft rises to its upper most position.
c. Lower main shaft and ensure main shaft locks in its upper most position.
28. Check telescopic operation as follows:
a. Ensure there is no axial play when lever is turned fully counterclockwise.
b. Ensure main shaft moves smoothly when lever is turned clockwise.