Disassembly / Assembly

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

1. Remove sliding yoke.




a. Place matchmarks on the sliding yoke and main shaft.
b. Remove the bolt.




2. Remove column upper bracket and column upper clamp.
Using a centering punch, mark the center of the 2 tapered-head bolts.
Using a 3 mm (0.12-0.16 inch) drill, drill into the 2 bolts.
Using a screw extractor, remove the 2 bolts.
3. Remove column tube support.
Remove the bolt.
Remove the tube support with lower column tube attachment.
Remove the tube attachment from the tube support.




4. Remove 2 energy absorbing plates.
a. Using pliers, remove the energy absorbing clip.
b. Remove the energy absorbing plate, energy absorbing guide and break away capsule.




c. To remove the lock nut, turn it clockwise.

HINT: This nut is left-handed one.

d. Remove the No.1 tilt lever lock bolt, tilt lever assembly and tilt sub lever.
e. Remove the break away bracket.




5. Remove main shaft assembly and lower bushing.
a. Using snap ring pliers, remove the snap ring from the shaft assembly.
b. Using an extension bar and a hammer, tap out the shaft assembly.




c. Using a screwdriver, tap out the bushing.
d. Using snap ring pliers, remove the snap ring from the shaft assembly.

INSPECTION




1. Inspect steering lock operation.
Check that the staring 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. Inspect key unlock warning switch.
5. If necessary, replace ignition switch with key unlock warning switch.
a. Remove the 2 screws from the upper bracket.
b. Remove the key cylinder.
c. Slide out the switch.
d. Install a new ignition switch with key unlock warning switch with the 2 screws.
6. AT:
Inspect key interlock solenoid.
If necessary, replace key interlock solenoid.




8. Inspect bearing.
Check the bearing rotation condition and check for abnormal noise. If the bearing is worn or damaged, replace the column tube.

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

1. Coat with molybdenum disulfide lithium base grease.




2. Install main shaft assembly and lower bushing.
Using snap ring pliers, install a new snap ring to the shaft assembly.
b. Install the shaft assembly into the column tube.
c. Coat a new bushing with molybdenum disulfide lithium base grease.
d. Using Special Service Tool (SST) 09612-22011 or equivalent, and a hammer, tap in the bushing.
e. Using snap ring pliers, install a new snap ring to the shaft assembly.




3. Install 2 energy absorbing plates.
a. Install the break away capsule.
b. Install the energy absorbing guide and absorbing plate.
c. Install the new energy absorbing clip.
4. Install column tube support.

NOTICE: If the attachment or support is deformed, replace it with a new one.

a. install the tube attachment to the tube support.
b. Install the support.

NOTICE: Make sure to install the support facing the correct direction.

c. Torque the bolt.
Torque: 20 Nm (15 ft. lbs.)

NOTICE: Tighten the bolt while holding the support to prevent it turning too. Be sure to tighten the bolt with the specified torque.




5. Install column upper bracket and column upper clamp.
Tighten the 2 new tapered-head bolts until the bolt heads break off.
6. Install sliding yoke.
Torque the bolt.
Torque: 35 Nm (26 ft. lbs.)