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Steering Column ASSY: Overhaul

WARNING: This page is about a different car, the 2005 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. (See  PRECAUTION  ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 

    Wait for 90 seconds after disconnecting the battery terminal to prevent the airbag working.

  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE STEERING WHEEL COVER LOWER NO. 2 
  5. REMOVE STEERING WHEEL COVER LOWER NO. 3 
  6. REMOVE HORN BUTTON ASSY 
    NOTE: If the airbag connector is disconnected with the ignition switch in the ON position, DTCs will be recorded.
    1. Using a torx® socket wrench, loosen the 2 torx® screws until the grooves along the screw circumference are caught on the screw case.
      Fig 1: Loosening 2 Torx® Screws
      G02609686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the horn button assy from the steering wheel and disconnect the airbag connector.
    3. Disconnect the horn wire harness.
    NOTE: When removing the horn button assy, take care not to pull on the airbag wire harness or horn wire harness.
    Fig 2: Disconnecting Horn Wire Harness
    G02609687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION:
    • When storing the horn button assy, keep the upper surface of the horn button assy facing upward.
    • Never disassemble the horn button assy.
    Fig 3: Storing Horn Button Assy Correct Position
    G02609688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE STEERING WHEEL ASSY 
    1. Remove the steering wheel assy set nut.
    2. Put 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 4: Putting Matchmarks On Steering Wheel Assy & Main Shaft Assy
    G02609689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE STEERING COLUMN COVER 
    1. Remove the 2 screws and steering column cover.
    Fig 5: Removing 2 Screws & Steering Column Cover
    G02609690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE  SPIRAL CABLE SUB-ASSY 
  10. REMOVE HEADLAMP DIMMER SWITCH ASSY (See  REPLACEMENT  ) 
  11. REMOVE WINDSHIELD WIPER SWITCH ASSY (See  REPLACEMENT  ) 
  12. REMOVE FRONT DOOR SCUFF PLATE LH (See  REPLACEMENT  ) 
  13. REMOVE COWL SIDE TRIM BOARD LH (See  REPLACEMENT  ) 
  14. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER LH (See  REPLACEMENT  ) 
  15. REMOVE INSTRUMENT PANEL SAFETY PAD INSERT SUB-ASSY NO. 1 (See  REPLACEMENT  ) 
  16. REMOVE HEATER TO FOOT DUCT NO. 3 
    1. Disengage the 3 claws and remove the air duct No. 3.
  17. SEPARATE STEERING INTERMEDIATE SHAFT ASSY 
    1. Loosen the bolt.
      Fig 6: Loosening Bolt
      G02609691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the 3 clips and separate the dust cover.
      Fig 7: Releasing 3 Clips
      G02609692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Align the matchmarks on the steering intermediate shaft assy and steering gear assy.
    4. Remove the bolt and separate the steering intermediate shaft assy.
    Fig 8: Aligning Matchmarks On Steering Intermediate Shaft Assy & Steering Gear Assy
    G02609693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE STEERING COLUMN ASSY 
    1. Disconnect the connectors and wire harness clamps.
    2. Remove the 3 bolts and steering column assy from the instrument panel reinforcement assy.
    Fig 9: Removing 3 Bolts & Steering Column Assy
    G02609694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STEERING INTERMEDIATE SHAFT ASSY 
    1. Align the matchmarks on the steering intermediate shaft assy and main shaft.
    2. Remove the bolt and steering intermediate shaft assy.
  20. REMOVE KEY CYLINDER LAMP ASSY (W/O ENGINE IMMOBILIZER SYSTEM) 
    Fig 10: Aligning Matchmarks On Steering Intermediate Shaft Assy & Main Shaft
    G02609695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILIZER SYSTEM) 
    1. Widen the claw hanging onto 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 11: Removing Transponder Key Amplifier
    G02609696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 a hole into the heads of the 2 bolts.
    3. Using a screw extractor, remove the 2 bolts and steering column upper w/ switch bracket assy.
    Fig 12: Removing 2 Bolts & Steering Column Upper W/ Switch Bracket Assy With Screw Extractor
    G02609697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE IGNITION SWITCH LOCK CYLINDER ASSY 
    1. Place the ignition switch lock cylinder assy in the ACC position.
    2. Push down the stop pin with a screwdriver, and pull out the cylinder assy.
    Fig 13: Placing Ignition Switch Lock Cylinder Assy In ACC Position
    G02609698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE UN-LOCK WARNING SWITCH ASSY 
    1. Disconnect the un-lock warning switch assy connector from the ignition or starter switch assy.
    2. Remove the un-lock warning switch assy by pushing up the center part and releasing the 2 claws.
      Fig 14: Removing Un-Lock Warning Switch Assy
      G02609699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the secondary locking device.
    4. Using a screwdriver, disengage the locking lug of terminals 1 and 2, and pull the terminals out from the rear side of the un-lock warning switch assy.
    Fig 15: Disengaging Locking Lug Of Terminals 1 & 2
    G02609700Courtesy 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 UPR.
  27. 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.
  28. INSTALL KEY INTER LOCK SOLENOID 
    1. Install the solenoid to the steering column bracket assy with the 2 screws.
  29. INSTALL UN-LOCK WARNING SWITCH ASSY 
    1. Install the un-lock warning switch assy.
    2. Connect terminals 1 and 2 of the un-lock warning switch assy connector.
    3. Connect the un-lock warning switch assy connector to the ignition or starter switch assy.
    Fig 16: Installing Un-Lock Warning Switch Assy
    G02609701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL IGNITION SWITCH LOCK CYLINDER ASSY 
    1. Make sure that the ignition switch lock cylinder assy is in 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 the ACC position.
  32. 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.
  33. INSTALL KEY CYLINDER LAMP ASSY (W/O ENGINE IMMOBILIZER SYSTEM) 
    Fig 17: Tightening 2 Tapered-Head Bolts
    G02609702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. 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 18: Installing Transponder Key Amplifier
    G02609703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL STEERING INTERMEDIATE SHAFT ASSY 
    1. Align the matchmarks on the steering intermediate shaft assy and main shaft.
    2. Temporarily install the steering intermediate shaft assy with the bolt.

      Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

      Fig 19: Aligning Matchmarks On Steering Intermediate Shaft Assy & Main Shaft
      G02609704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 3 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

    2. Connect the connectors.
    3. Connect the wire harness clamps to the steering column tube.
    Fig 20: Installing Steering Column Assy With 3 Bolts
    G02609705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. CONNECT STEERING INTERMEDIATE SHAFT ASSY 
    1. Align the matchmarks on the intermediate shaft assy and steering gear assy.
    2. Install the steering intermediate shaft assy with the bolt.

      Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

      Fig 21: Aligning Matchmarks On Intermediate Shaft Assy And Steering Gear Assy
      G02609706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the dust cover to the hole cover. Check that the 3 clips of the dust cover are securely fitted into the groove on the hole cover.
    Fig 22: Installing Dust Cover To Hole Cover
    G02609707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  39. INSTALL  SPIRAL CABLE SUB-ASSY 
  40. CENTER SPIRAL CABLE 
    1. Check that the ignition switch is OFF.
    2. Check that the battery negative terminal is separated.
      NOTE: After removing the terminal, wait for at least 90 seconds before starting the operation.
    3. Turn the cable counterclockwise by hand until it feels firm.
      Fig 23: Turning Cable Counterclockwise
      G02609708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Then rotate the cable clockwise about 2.5 turns to align the marks.

    HINT:

    The cable will rotate about 2.5 turns to both the left and right from the center.

    Fig 24: Rotating Cable Clockwise
    G02609709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL STEERING COLUMN COVER 
  42. 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.
  43. INSPECT STEERING WHEEL CENTER POINT 
  44. INSPECT HORN BUTTON ASSY (See  ON-VEHICLE INSPECTION  ) 
  45. 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 on 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 horn wire harness.
    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.
    4. Using a torx® socket wrench, tighten the 2 screws.

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

    Fig 25: Tightening 2 Screws
    G02609710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL STEERING WHEEL COVER LOWER NO. 3 
  47. INSTALL STEERING WHEEL COVER LOWER NO. 2 
  48. CONNECT BATTERY NEGATIVE TERMINAL 
  49. PERFORM INITIALIZATION (See  REPAIR INSTRUCTION  ) 

    Some systems need initialization when disconnecting the battery terminal.

  50. INSPECT SRS WARNING LIGHT (See  DIAGNOSTIC TROUBLE CODES CHECK/CLEAR  ) 
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