Disassembly and Reassembly

DISASSEMBLY

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

1. REMOVE TRANSPONDER KEY COIL AND KEY CYLINDER LAMP ASSEMBLY
Remove the screw, transponder key coil and key cylinder lamp assembly.





2. 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 - 4 mm (0.12 - 0.16 inch) drill, drill into the 2 bolts.
c. Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp.
3. REMOVE COLUMN TUBE SUPPORT
a. Remove the bolt and column tube support with the lower column tube attachment.
b. Remove the lower column tube attachment from the column tube support.





4. REMOVE 2 ENERGY ABSORBING PLATES
a. Using pliers, remove the 2 energy absorbing clips.
b. Remove the 2 energy absorbing plates and 2 energy absorbing plate guides.
5. REMOVE COLUMN PROTECTOR
Remove the 2 bolts and column protector.





6. REMOVE 2 TENSION SPRINGS
Using SST, remove the 2 tension springs.
SST 09703-30010
7. REMOVE TURN SIGNAL BRACKET
a. Using pliers, remove the tension spring.
b. Remove the 2 bolts and turn signal bracket.
8. REMOVE TILT LEVER ASSEMBLY
a. Remove the tension spring.
b. Remove the spring nut, tilt lever assembly and tilt lever link.
c. Remove the 2 bushings from the upper column tube sub-assembly.
9. REMOVE MAIN SHAFT ASSEMBLY WITH UPPER COLUMN TUBE SUB-ASSEMBLY





a. Using a hexagon wrench (6 mm), remove the 2 tilt steering shafts.
b. Remove the pawl retainer and main shaft assembly with the upper column tube sub-assembly.





c. Using a pin punch (5 mm) and a hammer, remove the No. 2 tilt steering shaft and pawl assembly.
10. REMOVE UPPER COLUMN TUBE SUB-ASSEMBLY FROM MAIN SHAFT ASSEMBLY





a. Bent the joint of the main shaft at right angles, leaving the cross ball in the No. 2 main shaft sub-assembly, separate the main shaft into the No. 1 main shaft with upper column tube sub-assembly and No. 2 main shaft sub-assembly.





b. Secure the No. 1 main shaft with upper column tube sub-assembly and SST in a vise.
SST 09316-60011 (09316-00051)





c. Using SST, compress the spring of the upper column tube sub-assembly.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04011)

NOTICE: Do not overtighten the SST.

d. Using snap ring expander, remove the snap ring and No. 1 main shaft.
11. REMOVE COMPRESSION SPRING, BEARING THRUST COLLAR AND BEARING





12. REMOVE MAIN SHAFT BUSHING
Using a screwdriver, tap out the main shaft bushing.

INSPECTION





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 key is at the ACC position.

3. INSPECT IGNITION SWITCH
4. IF NECESSARY, REPLACE IGNITION SWITCH
a. Remove the 2 screws and ignition switch from the column upper bracket.
b. Install a new ignition switch with the 2 screws.
5. INSPECT KEY UNLOCK WARNING SWITCH
6. IF NECESSARY, REPLACE KEY UNLOCK WARNING SWITCH
a. Slide the key unlock warning switch out of the column upper bracket.
b. Slide a new key unlock warning switch in the column upper bracket.
7. INSPECT KEY INTERLOCK SOLENOID
8. IF NECESSARY, REPLACE KEY INTERLOCK SOLENOID
a. Remove the 2 screws and key interlock solenoid.
b. Install a new key interlock 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 and transponder key amplifier.
b. Install a new transponder key amplifier with the 2 screws.





12. INSPECT BEARING
Check the bearing rotation condition and check for abnormal noise.
If the bearing is worn or damaged, replace the upper column tube sub-assembly.

REASSEMBLY

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

1. COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE





2. INSTALL MAIN SHAFT BUSHING
a. Coat a new main shaft bushing with molybdenum disulfide lithium base grease.
b. Using SST and a hammer, tap in the main shaft bushing.
SST 09612-22011
3. INSTALL COMPRESSION SPRING, BEARING THRUST COLLAR AND BEARING
4. INSTALL UPPER COLUMN TUBE SUB-ASSEMBLY TO MAIN SHAFT ASSEMBLY
a. Temporarily install the upper column tube sub-assembly to the No. 1 main shaft.





b. Secure the No. 1 main shaft with upper column tube sub-assembly and SST in a vise.
SST 09316-60011 (09316-00051)





c. Using SST, compress the spring of the upper column tube sub-assembly.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04011)

NOTICE: Do not overtighten the SST.

d. Using a snap ring expander, install a new snap ring and No. 1 main shaft.





e. Assemble the No. 1 main shaft with upper column tube sub-assembly and No. 2 main shaft sub-assembly.

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

5. INSTALL MAIN SHAFT ASSEMBLY WITH UPPER COLUMN TUBE SUB-ASSEMBLY





a. Using a pin punch (5 mm) and a hammer, install the pawl assembly with a new No. 2 tilt steering shaft.








HINT: Install a new No. 2 tilt steering shaft with the one having the mark corresponding to the mark stamped on the pawl assembly.

b. Install the main shaft assembly with the upper column tube sub-assembly and pawl retainer.





c. Using a hexagon wrench (6 mm), install the 2 tilt steering shafts.
Torque: 20 Nm (210 kgf-cm, 15 ft. lbs.)
6. INSTALL TILT LEVER ASSEMBLY





a. Install the 2 bushings to the upper column tube sub-assembly.
b. Install the tilt lever assembly with a new spring nut.

NOTICE: Make sure that the spring nut is installed facing in the correct direction.

c. Install the tilt lever link.





d. Install the tension spring.

NOTICE: Make sure that the tension spring is installed facing in the correct direction.





7. INSTALL TURN SIGNAL BRACKET
a. Install the turn signal bracket with the 2 bolts.
Torque: 2.9 Nm (30 kgf-cm, 26 inch lbs.)
b. Using pliers, install the tension spring.

NOTICE: Make sure that the tension spring is installed facing in the correct direction.





8. INSTALL 2 TENSION SPRINGS
Using SST, install the 2 tension springs.
SST 09703-30010
9. INSTALL COLUMN PROTECTOR
Install the column protector with the 2 bolts.
Torque: 6.1 Nm (60 kgf-cm, 52 inch lbs.)





10. INSTALL 2 ENERGY ABSORBING PLATES
a. Install the 2 new energy absorbing plate guides and energy absorbing plates.
b. Install the 2 new energy absorbing clips.
11. INSTALL COLUMN TUBE SUPPORT
a. Install the lower column tube attachment to the column tube support.
b. Install the column tube support with the lower column tube attachment with the bolt.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)





12. INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP
a. Install the column upper bracket and column upper clamp with 2 new tapered-head bolts.
b. Tighten the 2 tapered-head bolts until the bolt heads break off.
13. INSTALL TRANSPONDER KEY COIL AND KEY CYLINDER LAMP ASSEMBLY
Install the key cylinder lamp assembly and transponder key coil with the screw.