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Steering Column ASSY: Overhaul

  1. Precaution (See  AIR BAG SAFETY PRECAUTIONS  )  .
  2. Separate battery negative terminal  .
  3. Place front wheels facing straight ahead  .
  4. Remove steering wheel cover lower NO. 2  .
  5. Remove horn button assy  .
    Fig 1: Locating Steering Pad Torx Screws
    G01064728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If the airbag connector is disconnected with the ignition switch ON, DTCs will be recorded.
    1. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.
    2. Pull out the wheel pad from the steering wheel and disconnect the airbag connector.
      Fig 2: Locating Air Bag Connector & Identifying Safe Air Bag Handling Procedures
      G01064729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the terminal and horn connector.
    CAUTION:
    • When storing the wheel pad, keep the upper surface of the pad facing upward.
    • Never disassemble the wheel pad.
    NOTE: When removing the wheel pad, take care not to pull the airbag wire harness.
  6. Remove steering wheel assy  .
    1. Remove the steering wheel assy set nut.
    2. Place matchmarks on the steering wheel assy and main shaft assy.
    3. Using SST, remove the steering wheel assy.

    SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) 

    Fig 3: Matchmarking Steering Wheel & Main Shaft
    G01064730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Remove steering column lower cover  .
    1. Remove the 3 screws and steering column lower cover.
      Fig 4: Removing Lower Steering Column Cover
      G01064731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Remove steering column upper cover  .
  9. Remove spiral cable sub-assy  .

    (See  SPIRAL CABLE  )  .

  10. Remove headlamp dimmer switch assy  .

    (See  HEADLIGHT DIMMER SWITCH ASSY  )  .

  11. Remove windshield wiper switch assy  .

    (See  WINDSHIELD WIPER SWITCH ASSY  )  .

  12. Remove instrument panel finish panel sub-assy lower  .

    (See  INSTRUMENT PANEL SAFTY PAD SUB-ASSY  )  .

  13. Remove instrument panel insert sub-assy lwr LH  .

    (See  INSTRUMENT PANEL SAFTY PAD SUB-ASSY  )  .

  14. Separate steering intermediate shaft sub-assy  .
    1. Loosen the bolt A and remove the clamp from the steering column hole cover No.1.
    2. Separate the steering column hole cover No.2 from the steering column hole cover No.1.
      Fig 5: Separating Steering Column Hole Cover No. 2
      G01064732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Loosen the bolt B.
    4. Place matchmarks on the steering intermediate shaft sub-assy and steering gear assy.
      Fig 6: Placing Matchmarks On Steering Shaft & Steering Wheel
      G01064733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and separate the steering intermediate shaft sub-assy.
  15. Remove steering column assy  .
    1. Separate the connectors and wire harness clamps.
    2. Remove the 2 bolts, 2 nuts and steering column assy from the instrument panel reinforcement assy.
      Fig 7: Remove Steering Column Assy
      G01064734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove steering intermediate shaft sub-assy  .
    1. Place matchmarks on the steering intermediate shaft sub-assy and steering shaft universal joint assy.
      Fig 8: Placing Matchmarks & Removing Steering Intermediate Shaft Sub-Assy
      G01064735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and steering intermediate shaft subassy.
  17. Remove steering column hole cover sub-assy no.2  .
  18. Remove steering shaft universal joint assy  .
    1. Place matchmarks on the steering shaft universal joint assy and steering main shaft assy.
    2. Remove the bolt and steering shaft universal joint assy from the steering main shaft assy.
      Fig 9: Placing Matchmarks & Removing Steering Intermediate Shaft Sub-Assy
      G01064736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Remove key cylinder lamp assy (w/ illuminated entry system)  .
  20. Remove transponder key amplifier (w/engine immobiliser system)  .
    1. Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver.
      Fig 10: Removing Transponder Key Amplifier
      G01064737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull the transponder key amplifier toward the rear of the vehicle with the claw open.
    NOTE: Take care not to use excessive force to prevent the case from being damaged.
  21. Remove steering column upper w/switch bracket assy  .
    1. Using a centering punch, mark the center of the 2 tapered-head bolts.
    2. Using a 3-4 mm (0.12-0. 16 in.) drill, drill in to the 2 bolts.
    3. Using a screw extractor, remove the 2 bolts and steering column upper w/switch bracket assy.
      Fig 11: Removing Switch Bracket Assembly
      G01064738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. Remove steering column clamp upper  .
  23. Remove steering main shaft assy  .
    1. Using a snap ring expander, remove the steering main shaft snap ring (outer side).
      Fig 12: Removing Steering Main Shaft Snap Ring
      G01064739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft bushing.
      Fig 13: Removing Steering Main Shaft Assy
      G01064740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not drop the steering main shaft assy.
    3. Using a snap ring expander, remove the steering main shaft snap ring (inner side).
      Fig 14: Removing Steering Main Shaft Snap Ring (Inner Side)
      G01064741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Measure the steering main shaft length.
      Fig 15: Measuring Main Shaft Length
      G01064742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Standard length: 504.1 +/- 1 mm (19.846 +/- 0.039 in.) 

  24. Remove ignition switch lock cylinder assy  .
    1. Place the ignition switch lock cylinder assy at the ACC position.
      Fig 16: Removing Ignition Switch Lock Cylinder Assy
      G01064743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down the stop pin with a screwdriver, and pull out the cylinder assy.
  25. Remove un-lock warning switch assy  .
    1. Separate the unlock warning switch assy connector from the ignition or starter switch assy.
    2. Remove the unlock warning switch assy by pushing up the center part and releasing the 2 claws.
      Fig 17: Removing Unlock Warning Switch Assy
      G01064744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the secondary locking device.
      Fig 18: Disengaging The Secondary Locking Device
      G01064745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a small screwdriver, disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the un-lock waring switch assy rear side.
  26. Remove key interlock solenoid  .
    1. Remove the 2 screws and solenoid from the steering column bracket assy.
  27. Remove ignition or starter switch assy  .
    1. Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy upr.
  28. Install ignition or starter switch assy  .
    1. Install the ignition or starter switch assy to the steering column bracket assy upr with the 2 screws.
  29. Install key interlock solenoid  .
    1. Install the solenoid to the steering column bracket assy with the 2 screws.
  30. Install unlock warning switch assy  .
    1. Install the unlock warning switch assy.
      Fig 19: Installing UnLock Warning Switch Assy
      G01064746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the terminals 2 and 4 of the unlock warning switch assy connector.
    3. Connect the unlock warning switch assy connector to the ignition or starter switch assy.
  31. Install ignition switch lock cylinder assy  .
    1. Make sure the ignition switch lock cylinder assy at the ACC position.
    2. Install the ignition switch lock cylinder assy.
  32. Inspect steering lock operation  .
    1. Check that the steering lock mechanism is activated when removing the key.
    2. Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position.
  33. Install steering main shaft assy  .
    1. Using a snap ring expander, install a new steering main shaft snap ring (inner side) to the steering main shaft assy.
      Fig 20: Installing Steering Main Shaft Assy
      G01064747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the steering main shaft assy to the steering column tube.
      Fig 21: Installing Steering Main Shaft Snap Ring
      G01064748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy.
  34. Install steering main shaft bush  .
    1. Using SST and a hammer, install a new steering main shaft bush.

      SST 09608-06041 

      Fig 22: Installing Steering Main Shaft
      G01064749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. Install steering column upper w/switch bracket assy  .
    1. Temporarily install the steering column upper w/switch bracket assy and steering column upper clamp with 2 new tapered-head bolts.
      Fig 23: Identifying Tapered Head Bolts
      G01064750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 2 tapered-head bolts until the bolt heads break off.
  36. Install key cylinder lamp assy (w/ illuminated entry system)  .
  37. Install transponder key amplifier (w/engine immobiliser system)  .
    1. Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
      Fig 24: Displaying Transponder Key Amplifier Position For Alignment
      G01064751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the transponder key amplifier up and connect it to the upper bracket.
    NOTE: Take care not to push the amplifier up with excessive force to prevent it from being damaged.
  38. Install steering shaft universal joint assy  .
    1. Align the matchmarks on the steering universal joint assy and steering main shaft assy.
      Fig 25: Installing Steering Shaft Universal Joint Assy
      G01064752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the steering universal joint assy with the bolt.

    Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

  39. Install steering column hole cover sub-assy no. 2  .
    1. Install the steering column hole cover sub-assy No.2 to the steering intermediate shaft sub-assy.
      Fig 26: Installing Steering Column Hole Cover Sub-Assy No.2
      G01064753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. Temporarily tighten steering intermediate shaft sub-assy  .
    1. Align the matchmarks on the steering intermediate shaft sub-assy and steering main shaft assy.
      Fig 27: Aligning Matchmarks On Steering Intermediate Shaft
      G01064754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the steering intermediate shaft sub-assy with the bolt.
  41. Install steering column assy  .
    1. Install the steering column assy with the 2 bolts and nuts.
      Fig 28: Installing Steering Column Assy
      G01064755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 

    2. Connect the connectors.
    3. Connect the wire harness clamps to the steering column tube.
  42. Connect steering intermediate shaft sub-assy  .
    1. Align the matchmarks on the intermediate shaft sub-assy and steering gear assy.
    2. Install the bolt.
      Fig 29: Locating Matchmarks & Installing Bolt
      G01064756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

    3. Tighten the bolt A.

      Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

    4. Install the steering column hole cover No.2 to the steering hole cover No. 1.
    5. Connect the clamp to the steering column hole cover No.1 and tighten the bolt B.
      Fig 30: Locating Bolts A & B
      G01064757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. Place front wheels facing straight ahead  .
  44. Inspect spiral cable sub-assy 

    (See  SPIRAL CABLE  )  .

  45. Install spiral cable sub-assy  .

    (See  SPIRAL CABLE  )  .

  46. Center spiral cable  .
    1. Check that the ignition switch is OFF.
    2. Check that the battery negative terminal is separated.
      NOTE: Do not start the operation for 90 seconds after removing the terminal.
    3. Turn the cable counterclockwise by hand until it becomes harder to turn.
      Fig 31: Turning Cable Counterclockwise
      G01064758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Then rotate the cable clockwise about 2.5 turns to align the marks.
      Fig 32: Rotating Cable Clockwise
      G01064759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: The cable will rotate about 2.5 turns to either right or left of the center.
  47. Install steering wheel assy  .
    1. Align the matchmarks on the steering wheel assy and steering main shaft assy.
    2. Install the steering wheel assy set nut.

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    3. Connect the connector.
  48. Install horn button assy  .
    NOTE:
    • Never use airbag parts removed from another vehicle. When replacing parts, replace with new ones.
    • Make sure the wheel pad is installed with the specified torque.
    • If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one.
    • When installing the wheel pad, take care so that the wirings do not interfere with other parts and that they are not pinched between other parts.
    1. Connect the terminal.
    2. Connect the airbag connector.
    3. Install the steering wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case.
      Fig 33: Locating Steering Pad Torx Screws
      G01064760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a torx socket wrench, torque the 2 screws.

    Torque: 8.8 N.m (90 kgf.cm, 78 in.lbf) 

  49. Inspect SRS warning light (see  AIR BAG WARNING LIGHT CHECK  )  .
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