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Section 599 (Steering Column): Overhaul

WARNING: This page is about a different car, the 2004 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. PRECAUTION (See  AIR BAG SAFETY PRECAUTIONS  ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL (See  AIR BAG SAFETY PRECAUTIONS  ) 
  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE STEERING WHEEL COVER LOWER NO.2 (See  HORN  ) 
  5. REMOVE HORN BUTTON ASSY (See  HORN  ) 
  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.

      Using SST, remove the steering wheel assy. SST 09950-50013 (09951-05010, 09952-05010,09953-05020, 09954-05021)

    Fig 1: Placing Matchmarks On Steering Wheel Assy
    G03034320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE STEERING COLUMN COVER LWR 
    1. Remove the 3 screws and steering column cover LWR.
    Fig 2: Removing Steering Column Cover Screw
    G03034321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE STEERING COLUMN COVER UPPER 
  9. REMOVE SPIRAL CABLE SUB-ASSY (See  SPIRAL CABLE  ) 
  10. REMOVE HEADLAMP DIMMER SWITCH ASSY (See  REPLACEMENT  ) 
  11. REMOVE WINDSHIELD WIPER SWITCH ASSY (See  REPLACEMENT  ) 
  12. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (See  REPLACEMENT  ) 
  13. REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (See  REPLACEMENT  ) 
  14. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Loosen the bolt A and remove the clamp from the steering intermediate shaft sub-assy.
    2. Loosen the bolt B.
      Fig 3: Removing Steering Intermediate Shaft Sub-Assy Bolt And Clamp
      G03034322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place matchmarks on the steering intermediate shaft sub-assy and steering gear assy.
    4. Remove the bolt and separate the steering intermediate shaft sub-assy.
    Fig 4: Placing Matchmarks On Steering Intermediate Shaft Sub-Assy
    G03034323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 5: Removing Steering Column Assy From Instrument Panel
    G03034324Courtesy 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.
    2. Remove the bolt and steering intermediate shaft subassy.
    Fig 6: Placing Matchmarks On Steering Intermediate Shaft Sub-Assy
    G03034325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 
  18. REMOVE TRANSPONDER KEY AMPLIFIER (W/ENGINE IMMOBILIZER SYSTEM) 
    1. Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver.
    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.
    Fig 7: Removing Transponder Key Amplifier Engine Immobilizer System
    G03034326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT STEERING MAIN SHAFT ASSY 
    1. Measure the steering main shaft length.

      Standard length: 504.5 +/- 1 mm (19.862 +/- 0.039 in.) 

    If the length is out of specification, replace the steering column assy with a new one.

    Fig 8: Measuring Steering Main Shaft Length
    G03034327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 to 4 mm (0.12 to 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.
  21. REMOVE STEERING COLUMN CLAMP UPPER 
    Fig 9: Removing Steering Column Upper W/Switch Bracket Assy With Screw Extractor
    G03034328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE STEERING MAIN SHAFT ASSY 
    1. Using a snap ring expander, remove the steering main shaft snap ring (outer side).
      Fig 10: Removing Steering Main Shaft Snap Ring
      G03034329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft bushing.
      NOTE: Be careful not to drop the steering main shaft assy.
      Fig 11: Removing Steering Main Shaft Assy and Steering Main Shaft Bush
      G03034330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a snap ring expander, remove the steering main shaft snap ring (inner side).
    Fig 12: Removing Steering Main Shaft Snap Ring
    G03034331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY 
    1. Place the ignition switch lock cylinder assy at the ACC position.
    2. Push down the stop pin with a screwdriver, and pull out the cylinder assy.
    Fig 13: Pushing Down Stop Pin With A Screwdriver
    G03034332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE UNLOCK 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 14: Pushing Up Center Part And Releasing Claws
      G03034333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the secondary locking device.
    4. Using a small screwdriver, disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the unlock warning switch assy rear side.
    Fig 15: Disengaging Locking Lug Of Terminals Using A Small Screwdriver
    G03034334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE KEY INTER LOCK SOLENOID 
    1. Remove the 2 screws and solenoid from the steering column bracket assy.
  26. REMOVE IGNITION OR STARTER SWITCH ASSY 
    1. Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy UPPER.
  27. INSTALL IGNITION OR STARTER SWITCH ASSY 
    1. Install the ignition or starter switch assy to the steering column bracket assy UPPER with the 2 screws.
  28. INSTALL KEY INTER LOCK SOLENOID 
    1. Install the solenoid to the steering column bracket assy with the 2 screws.
  29. INSTALL UNLOCK WARNING SWITCH ASSY 
    1. Install the unlock warning switch assy.
    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.
    Fig 16: Connecting Unlock Warning Switch Assy Connector
    G03034335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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.
  31. 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.

    HINT:

    If there is any abnormality, replace the ignition switch lock cylinder assy.

  32. 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.
    2. Install the steering main shaft assy to the steering column tube.
      Fig 17: Installing New Steering Main Shaft Snap Ring Using A Snap Ring Expander
      G03034336Courtesy 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.
    Fig 18: Installing New Steering Main Shaft Snap Ring Using A Snap Ring Expander
    G03034337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL STEERING MAIN SHAFT BUSH 
    1. Using SST and a hammer, install a new steering mainshaft bushing.

      SST 09608-06041

    Fig 19: Installing Steering Main Shaft Bush Using SST And A Hammer
    G03034338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. 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.
    2. Tighten the 2 tapered-head bolts until the bolt heads break off.
    Fig 20: Installing Steering Column Upper Clamp With New Tapered-Head Bolts
    G03034339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 
  36. INSTALL TRANSPONDER KEY AMPLIFIER (W/ENGINE IMMOBILIZER SYSTEM) 
    1. Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
    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.
    Fig 21: Installing Transponder Key Amplifier (w/Engine Immobilizer System)
    G03034340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. TEMPORARILY TIGHTEN STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Align the matchmarks on the steering intermediate shaft sub-assy and steering main shaft assy.
    2. Temporarily install the steering intermediate shaft subassy with the bolt.
    Fig 22: Aligning Matchmark On Steering Intermediate Shaft Sub-Assy
    G03034341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 2 bolts and nuts.

      Torque: 21 NVm (210 kgfVcm, 15 ftVlbf) 

    2. Connect the connectors.
    3. Connect the wire harness clamps to the steering column tube.
    Fig 23: Installing Steering Column Assy
    G03034342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Align the matchmarks on the intermediate shaft sub-assy and steering gear assy.
    2. Install the bolt.

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

      Fig 24: Aligning Matchmarks On Intermediate Shaft Sub-Assy
      G03034343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the bolt A.

      Torque: 35 NVm (360 kgfVcm, 26 ftVlbf) 

    4. Connect the clamp to the steering intermediate shaft sub-assy and tighten the bolt B.
    Fig 25: Connecting Clamp To Steering Intermediate Shaft Sub-Assy
    G03034344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  41. INSPECT SPIRAL CABLE SUB-ASSY (See  SPIRAL CABLE  ) 
  42. INSTALL SPIRAL CABLE SUB-ASSY (See  SPIRAL CABLE  ) 
  43. CENTER SPIRAL CABLE (See  SPIRAL CABLE  ) 
  44. INSTALL STEERING COLUMN COVER UPPER 
  45. INSTALL STEERING COLUMN COVER LWR 
    1. Install the steering column cover LWR with the 3 screws.
  46. 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.
  47. INSTALL HORN BUTTON ASSY (See  HORN  ) 
  48. CONNECT BATTERY NEGATIVE TERMINAL 
  49. INSPECT SRS WARNING LIGHT (See  AIR BAG WARNING LIGHT INTERMITTENT  ) 
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