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Steering Column ASSY: Overhaul

WARNING: This page is about a different car, the 2003 Lexus ES 300. 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  SYSTEM OPERATION CHECK  ) 
  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE STEERING WHEEL COVER LOWER NO. 2 
  5. REMOVE CONNECTOR COVER 
  6. REMOVE STEERING PAD SWITCH 
    1. Remove the 2 screws.
    2. Disconnect the connector and remove the steering pad switch.
  7. REMOVE HORN BUTTON ASSY (See  HORN BUTTON ASSEMBLY  ) 
  8. REMOVE STEERING WHEEL ASSY 
    1. Remove the steering wheel assy set nut.
    2. Place matchmarks on the steering wheel assy and steering main shaft assy.
    3. Using SST, remove the steering wheel assy.
      1. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
      Fig 1: Removing Steering Wheel Assembly Using SST
      G01328519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT DOOR SCUFF PLATE LH (See  REPLACEMENT  ) 
  10. REMOVE INSTRUMENT PANEL SUB-ASSY UPPER (See  REPLACEMENT  ) 
  11. REMOVE INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (See  REPLACEMENT  ) 
  12. REMOVE HEATER TO FOOT DUCT NO.3 (See  REPLACEMENT  ) 
  13. REMOVE STEERING COLUMN COVER LWR NO. 2 
    1. Remove the steering column cover lower No. 2.
      Fig 2: Removing Steering Column Cover Lower No. 2
      G01328520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STEERING COLUMN COVER 
    1. Remove the 3 screws and steering column cover.
      Fig 3: Removing 3 Screws And Steering Column Cover
      G01328521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TURN SIGNAL SWITCH ASSY 
    1. Disconnect the 3 connectors.
    2. Disconnect the airbag connector.
    3. Remove the 3 screws and turn signal switch assy.
  16. REMOVE INSTRUMENT PANEL FINISH PLATE (See  REPLACEMENT  ) 
  17. DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY 
    1. Place the ignition switch lock cylinder assy at the key ACC position.
    2. Remove the cable cap claw from the key interlock and pull out the floor shift parking lock cable assy.
      Fig 4: Pulling Out Floor Shift Parking Lock Cable Assembly
      G01328522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT STEERING SLIDING YOKE SUB-ASSY 
    1. Place the matchmarks on the steering sliding yoke sub-assy and intermediate shaft sub-assy.
    2. Remove the bolt and disconnect the steering sliding yoke sub-assy.
      Fig 5: Removing Bolt And Disconnecting Steering Sliding Yoke Sub-Assembly
      G01328523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE STEERING COLUMN HOLE COVER SUB-ASSY NO. 2 
    1. Remove the hose clamp.
    2. Remove the steering column hole cover sub-assy NO. 2.
  20. REMOVE STEERING COLUMN ASSY 
    1. Disconnect the connectors and wire harness clamps.
    2. Disconnect the driver side junction block.
    3. Remove the 2 nuts, bolt and steering column assy from the instrument panel reinforcement assy.
      Fig 6: Removing 2 Nuts, Bolt And Steering Column Assembly From Instrument Panel Reinforcement Assembly
      G01328524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Place the matchmarks on the steering intermediate shaft sub-assy and steering gear assy.
    2. Remove the bolt and steering intermediate shaft sub-assy.
      Fig 7: Removing Bolt And Steering Intermediate Shaft Sub-Assembly
      G01328525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE STEERING SLIDING YOKE SUB-ASSY 
    1. Place the matchmarks on the steering sliding yoke sub-assy and steering main shaft assy.
    2. Remove the bolt and steering yoke sub-assy.
      Fig 8: Removing Bolt And Steering Yoke Sub-Assembly
      G01328526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE TRANSPONDER KEY AMPLIFIER 
    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.
      Fig 9: Removing Transponder Key Amplifier
      G01328527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Take care not to use excessive force to prevent the case from being damage.
  24. 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 10: Removing 2 Bolts And Steering Column Upper W/Switch Bracket Assembly Using Screw Extractor
      G01328528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. 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 ignition switch lock cylinder assy.
      Fig 11: Pulling Out Ignition Switch Lock Cylinder Assembly By Pushing Down Stop Pin With Screwdriver
      G01328529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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 screws.
      Fig 12: Removing Un-Lock Warning Switch Assembly By Pushing Up Center Part And Releasing 2 Screws
      G01328530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE IGNITION OR STARTER SWITCH ASSY 
    1. Remove the 2 screws and ignition or starter switch assy from the steering column upper w/switch bracket assy.
  28. INSTALL IGNITION OR STARTER SWITCH ASSY 
    1. Install the ignition switch assy to the steering column upper w/switch bracket assy with the 2 screws.
  29. INSTALL UN-LOCK WARNING SWITCH ASSY 
    1. Install the un-lock warning switch assy.
    2. Connect the un-lock warning switch assy connector to the ignition or starter switch assy.
  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.
  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.
      Fig 13: Tightening 2 Tapered-Head Bolts Until Bolt Heads Break Off
      G01328531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL TRANSPONDER KEY AMPLIFIER 
    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.
      Fig 14: Installing Transponder Key Amplifier
      G01328532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Take care not to push the amplifier up with excessive force to prevent it from being damaged.
  34. INSTALL STEERING SLIDING YOKE SUB-ASSY 
    1. Align the matchmarks on the steering sliding yoke sub-assy and steering main shaft assy.
    2. Install the steering sliding yoke sub-assy with the bolt.
      1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 
      Fig 15: Aligning Matchmarks On Steering Sliding Yoke Sub-Assembly And Steering Main Shaft Assembly
      G01328533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY NO. 2 
    1. Install the steering column hole cover sub-assy NO. 2.
    2. Install the hose clamp.
  36. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Align the matchmarks on the intermediate shaft sub-assy and steering gear assy.
    2. Install the steering intermediate shaft sub-assy with the bolt.
      1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 
      Fig 16: Aligning Matchmarks On Intermediate Shaft Sub-Assembly And Steering Gear Assembly
      G01328534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL STEERING COLUMN ASSY 
    1. Install the steering column assy with the 2 nuts and bolt.
      1. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 
    2. Connect the driver side junction block.
    3. Connect the connectors and wire harness clamps.
      Fig 17: Installing Steering Column Assembly With 2 Nuts And Bolt
      G01328535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. CONNECT STEERING SLIDING YOKE SUB-ASSY 
    1. Align the matchmarks on the steering sliding yoke sub-assy and steering intermediate shaft sub-assy.
    2. Connect the steering sliding yoke sub-assy with the bolt.
      1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 
      Fig 18: Aligning Matchmarks On Steering Sliding Yoke Sub-Assembly And Steering Intermediate Shaft Sub-Assembly
      G01328536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY 
    1. Place the ignition switch lock cylinder assy at the key ACC position.
    2. Install the floor shift parking lock cable assy.
  40. INSPECT CHECK KEY INTERLOCK OPERATION (See  ON-VEHICLE INSPECTION  ) 
  41. INSTALL INSTRUMENT PANEL FINISH PLATE (See  REPLACEMENT  ) 
  42. INSTALL TURN SIGNAL SWITCH ASSY 
    1. Install the turn signal switch assy with the 3 screws.
    2. Connect the airbag connector.
    3. Connect the 3 connectors.
  43. INSPECT SPIRAL CABLE SUB-ASSY (See  REMOVAL & INSTALLATION  ) 
  44. INSTALL STEERING COLUMN COVER 
    1. Install the steering column cover with the 3 screws.
  45. INSTALL STEERING COLUMN COVER LWR NO. 2 
  46. INSTALL HEATER TO FOOT DUCT NO.3 (See  REPLACEMENT  ) 
  47. INSTALL INSTRUMENT PANEL INSERT SUB-ASSY LOWER LH (See  REPLACEMENT  ) 
  48. INSTALL INSTRUMENT PANEL SUB-ASSY UPPER (See  REPLACEMENT  ) 
  49. INSTALL FRONT DOOR SCUFF PLATE LH (See  REPLACEMENT  ) 
  50. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  51. 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.
      1. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 
  52. INSPECT HORN BUTTON ASSY (See  HORN BUTTON ASSEMBLY  ) 
  53. INSTALL HORN BUTTON ASSY (See  HORN BUTTON ASSEMBLY  page 60-14) 
  54. INSTALL STEERING PAD SWITCH 
    1. Connect the connector.
    2. Install the steering pad switch with the 2 screws.
  55. INSTALL CONNECTOR COVER 
  56. INSTALL STEERING WHEEL COVER LOWER NO. 2 
  57. INSPECT SRS WARNING LIGHT (See  SYSTEM OPERATION CHECK  ) 
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