Steering Column: Service and Repair

STEERING COLUMN ASSEMBLY

Components:

REMOVAL
1. PRECAUTION
Refer to Restraint Systems Service Precautions.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working.
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

4. REMOVE NO.2 LOWER STEERING WHEEL COVER
a. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the steering wheel cover lower No. 2.

5. REMOVE NO.3 LOWER STEERING WHEEL COVER
a. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the No. 3 lower steering wheel cover.
6. REMOVE STEERING PAD

7. REMOVE STEERING WHEEL ASSEMBLY
a. Remove the steering wheel assembly set nut.
b. Place matchmarks on the steering wheel assembly and main shaft assembly.
c. Using SST, remove the steering wheel assembly.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

8. REMOVE LOWER STEERING COLUMN COVER
a. Remove the 2 screws.
b. Disengage the 2 claws to remove the lower steering column cover.

9. REMOVE UPPER STEERING COLUMN COVER
a. Disengage the claw and then remove the upper steering column cover.
10. REMOVE SPIRAL CABLE SUB-ASSEMBLY
11. REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY
12. REMOVE FRONT FLOOR FOOTREST
13. REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab)
14. REMOVE FRONT DOOR SCUFF PLATE LH (for Access Cab)
15. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
16. REMOVE COWL SIDE TRIM BOARD LH (for Regular Cab)
17. REMOVE COWL SIDE TRIM BOARD LH (for Access Cab)
18. REMOVE COWL SIDE TRIM BOARD LH (for Double Cab)
19. REMOVE INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake)
20. REMOVE INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake)
21. REMOVE INSTRUMENT PANEL LOWER LH
22. REMOVE INSTRUMENT PANEL COVER SUB-ASSEMBLY LOWER

23. REMOVE STEERING COLUMN HOLE COVER
a. Disengage the 4 clips and remove the steering column hole cover.
24. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
a. Remove the No. 1 engine under cover subassembly with the 4 bolts.

25. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT
a. Mark matchmarks on the power steering gear assembly and No. 2 steering intermediate shaft.
b. Remove bolt C and No. 2 steering intermediate shaft from the power steering gear assembly
26. REMOVE STEERING SLIDING YOKE
a. Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2 and steering intermediate shaft assembly.
b. Remove bolts A and B from the steering sliding yoke.
c. Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2.
d. Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove.

27. REMOVE STEERING COLUMN ASSEMBLY
a. Disconnect the connectors and wire harness clamps.
b. Remove the bolt and 2 nuts, then remove the steering column assembly from the instrument panel reinforcement assembly.

DISASSEMBLY

1. REMOVE STEERING INTERMEDIATE SHAFT ASSEMBLY
a. Place matchmarks on the steering intermediate shaft sub-assembly and steering shaft.
b. Remove the bolt and steering intermediate shaft sub-assembly.

2. REMOVE TILT LEVER RETURN SPRING
a. Remove the tilt lever return spring from the steering upper support bracket and steering tilt lever.

3. REMOVE UPPER STEERING COLUMN CLAMP
a. Using a centering punch, make the center of the 2 taped- hand bolts.
b. Using a drill, make a hole in the 2 steering lock set bolts and set a screw extractor.
c. Using the screw extractor, remove the steering column bracket assembly upper and upper steering column clamp from the steering column tube upper.

4. REMOVE TRANSPONDER KEY AMPLIFIER
a. Widen the claw hung on the upper bracket by approximately 1.0 mm (0.039 inch) using a screwdriver.
b. Pull the transponder key amplifier toward the rear of the vehicle with the claw open.

NOTICE: Take care not to apply excessive force to prevent the case from being damaged.

5. REMOVE IGNITION SWITCH LOCK CYLINDER & KEY SET
a. Place the ignition switch lock cylinder assembly in the accessory position.
b. Insert screwdriver in the steering column bracket assembly upper as shown in the illustration. Then slide ignition switch lock cylinder assembly until the claw of the ignition switch lock cylinder assembly comes into contact with the steering column bracket assembly upper stopper.

c. Insert a screwdriver into the steering column bracket assembly upper as shown in the illustration. Then tilt the screwdriver as shown in the illustration to disengage the claw of the ignition lock cylinder assembly and remove the cylinder.

HINT: When the ignition lock cylinder assembly disengages, a click sound is heard.

6. REMOVE UN-LOCK WARNING SWITCH ASSEMBLY
a. Disconnect the un-lock warning switch assembly connector from the ignition or start switch assembly.
b. Remove the un-lock warning switch assembly toward the rear of the vehicle by pushing up the center part.

7. REMOVE IGNITION OR STARTER SWITCH ASSEMBLY
a. Disengage the 2 claws and ignition or starter switch assembly from the steering column bracket assembly upper.

8. REMOVE KEY INTER LOCK SOLENOID (for Automatic Transmission)
a. Remove the 2 screws and key inter lock solenoid from the steering column bracket assembly upper.

9. REMOVE STEERING MAIN SHAFT ASSEMBLY
a. Using a screwdriver, remove the steering column No. 1 ring from the steering main shaft.

b. Using a snap ring expander, remove the snap ring and No. 1 main shaft.
c. Remove the compression spring, bearing thrust collar and bearing from the No. 1 main shaft.

10. REMOVE NO.1 TILT STEERING SUPPORT COLLAR
a. Using a brass bar, hammer and vise, gently strike the central part of the steering column bracket spacer and remove it.
b. Remove the No. 1 tilt steering support collar from the steering column tube lower.

REASSEMBLY
1. INSTALL NO.1 TILT STEERING SUPPORT COLLAR
a. Install the No. 1 tilt steering support collar from the steering column tube lower.

b. Using a hammer and vise, install the steering column bracket spacer.

NOTICE:
^ The inclination of the steering column bracket spacer should be within +- 15° when installing, as shown in the illustration.
^ The turning angle of the No. 1 tilt steering support collar should be within +- 15° when installing.

2. INSTALL STEERING MAIN SHAFT ASSEMBLY
a. Install the steering main shaft onto the steering column tube upper and steering column tube lower.

b. Using a snap ring expander, install a new snap ring onto the main shaft.

c. Install the steering column No. 1 ring onto the steering main shaft.
3. INSTALL KEY INTER LOCK SOLENOID (for Automatic Transmission)
a. Install the key inter lock solenoid onto the steering column bracket assembly upper with 2 screws.
4. INSTALL IGNITION OR STARTER SWITCH ASSEMBLY
a. Engage the ignition starter switch assembly into the steering column bracket assembly upper with the 2 claws.
5. INSTALL UN-LOCK WARNING SWITCH ASSEMBLY
a. Install the un-lock warning switch assembly onto the steering column bracket assembly upper.
b. Connect the un-lock warning switch assembly connector to the ignition switch assembly.
6. INSTALL IGNITION SWITCH LOCK CYLINDER & KEY SET
a. Make sure that the ignition switch lock cylinder assembly is in the accessory position.
b. Install the ignition switch lock cylinder assembly.

HINT: When the ignition lock cylinder assembly engages, a click sound is heard.

7. INSTALL TRANSPONDER KEY AMPLIFIER

NOTICE: Take care not to push the amplifier up forcibly to prevent it from being damaged.

a. Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
b. Push up the transponder key amplifier and connect it to the upper bracket.
8. INSPECT STEERING LOCK OPERATION
a. Check that the steering mechanism is activated when removing the key.
b. Check that the steering mechanism is deactivated when inserting the key and turning it to ACC position.
9. INSTALL UPPER STEERING COLUMN CLAMP
a. Provisionally install the steering column bracket assembly upper and steering column upper clamp with the 2 new tapered-head bolts.
b. Tighten the 2 tapered-head bolts until the bolt heads break off.

10. INSTALL TILT LEVER RETURN SPRING
a. Install the tilt lever return spring onto the bracket and steering tilt lever.

11. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
a. Align the matchmarks on the steering intermediate shaft sub-assembly and steering main shaft assembly.
b. Temporarily install the steering intermediate shaft sub-assembly with the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)

INSTALLATION

1. INSTALL STEERING COLUMN ASSEMBLY
a. Install the steering column assembly with the 2 nuts and bolt.
Torque: 21 Nm (210 kgf-cm, 16 ft. lbs.)
b. Connect each of the connectors to the steering column assembly.
c. Connect the wire harness clamps to the steering column assembly.

CAUTION: Use a shop rag to wipe any dirt off the installation plane and column body side.

NOTICE: Be careful not to scratch or soil the installation plane of the steering column.

2. INSTALL NO.2 STEERING INTERMEDIATE SHAFT
a. Align the matchmarks on the power steering gear and No. 2 steering intermediate shaft.
b. Install the No. 2 steering intermediate shaft onto the steering gear box with bolt C.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.) for bolt C
3. INSTALL STEERING SLIDING YOKE
a. Align the matchmarks on the steering column and steering sliding yoke.
b. Install the steering sliding yoke onto the steering column assembly and slide it upward.
c. Align the matchmarks on the intermediate shaft subassembly No. 2 and steering sliding yoke.
d. Install the sliding yoke onto the intermediate shaft sub-assembly No. 2 with bolts A and B.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.) for bolt A, B
4. INSTALL NO.1 ENGINE UNDER COVER SUB-ASSEMBLY
a. Install the No. 1 engine under cover sub-assembly with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

5. INSTALL STEERING COLUMN HOLE COVER
a. Install the steering column hole cover with the 4 clips.
6. INSTALL LOWER INSTRUMENT PANEL LH
7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
8. INSTALL INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake)
9. INSTALL INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake)
10. INSTALL COWL SIDE TRIM BOARD LH (for Regular Cab)
11. INSTALL COWL SIDE TRIM BOARD LH (for Access Cab)
12. INSTALL COWL SIDE TRIM BOARD LH (for Double Cab)
13. INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab)
14. INSTALL FRONT DOOR SCUFF PLATE LH (for Access Cab)
15. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)
16. INSTALL FRONT FLOOR FOOTREST
17. INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY
18. INSTALL SPIRAL CABLE SUB-ASSEMBLY
19. INSTALL UPPER STEERING COLUMN COVER
a. Engage the claw and then install the steering column cover upper.
20. INSTALL LOWER STEERING COLUMN COVER
a. Engage the 2 claws.
b. Install the steering column cover lower with the 2 screws.
21. INSTALL STEERING WHEEL ASSEMBLY
a. Align the matchmarks on the steering wheel assembly and steering main shaft assembly.
b. Install the steering wheel assembly set nut.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
22. INSTALL STEERING PAD
23. INSTALL NO.3 LOWER STEERING WHEEL COVER
a. Engage the claw and install the No. 3 lower steering wheel cover onto the steering wheel assembly.
24. INSTALL NO.2 LOWER STEERING WHEEL COVER
a. Engage the claw and install the No. 2 lower steering wheel cover onto the steering wheel assembly.
25. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
27. INSPECT SRS WARNING LIGHT