Steering Column ASSY: Overhaul

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

Fig 1: Putting Matchmarks On Steering Wheel Assy And Main Shaft Assy

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1. Remove the 2 screws and steering column cover LWR and the steering column cover UPR.

HINT:

• Tilt the steering column assy to the lowermost position when removing the steering column upper cover.
• Tilt it to the uppermost position when removing the steering column lower cover.

Fig 2: Removing Steering Column Cover

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1. Turn back the floor carpet and remove the 2 clips and the column hole cover silencer sheet.

Fig 3: Removing Column Hole Cover Silencer Sheet

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1. Put matchmarks on the steering intermediate shaft assy No. 2 and the steering intermediate shaft.
2. Remove bolt and separate the steering intermediate shaft assy No. 2 from the steering intermediate shaft.

Fig 4: Putting Matchmarks On Steering Intermediate Shaft Assy

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1. Disconnect the connectors and the wire harness clamps from the steering column assy.
2. Remove the 3 bolts and the steering column assy.

Fig 5: Removing 3 Bolts Securing The Steering Column Assy

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1. Put matchmarks on the steering intermediate shaft assy No. 2 and steering main shaft assy.
2. Remove the bolt and steering intermediate shaft assy No. 2.

Fig 6: Putting Matchmarks On Steering Intermediate Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Widen the claw hung onto the upper bracket by approximately 1.0 mm (0.039 in.) using a screwdriver.
2. Pull the transponder key amplifier towards the rear of the vehicle with the claw open.

Fig 7: Pulling Transponder Key Amplifier

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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 in the 2 bolt heads.
3. Using a screw extractor, remove the 2 bolts, steering column upper w/ switch bracket assy and steering column clamp upper.

Fig 8: Removing Steering Column Upper W/ Switch Bracket Assy

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1. Secure the steering column tube in a vise. Insert aluminum plates between the steering column tube and the vise to prevent damage.
   NOTE: Do not overtighten the vise.
2. Using a snap ring expander, remove the steering main shaft snap ring (outer side).
   Fig 9: Securing Steering Column Tube In Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft bearing.
   NOTE: Be careful not to drop the steering main shaft assy.
   Fig 10: Removing Steering Main Shaft Assy And Steering Main Shaft Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, remove the steering main shaft snap ring (inner side).
   Fig 11: Removing Steering Main Shaft Snap Ring (Inner Side)

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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 12: Removing Ignition Switch Lock Cylinder Assy

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1. Separate 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 on the center part and disengaging the 2 claws.
3. Manual Transaxle:

   Remove the clamp from the steering column upper bracket assy.

   Fig 13: Separating UnLock Warning Switch Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Automatic Transaxle:

   Disengage the secondary locking device.

5. Automatic Transaxle:

   Using a screwdriver, disengage the locking lug of terminals 3 and 4, and pull the terminals out from the un-lock warning switch assy connector rear side.

   Fig 14: Disengaging Secondary Locking Device

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1. Remove the 2 screws and key inter lock solenoid from the steering column upper bracket assy.

1. Remove the 2 screws and ignition or starter switch assy from the steering column upper bracket assy.

1. Install the ignition or starter switch assy to the steering column upper bracket assy with the 2 screws.

1. Install the key inter lock solenoid to the steering column upper bracket assy with the 2 screws.

1. Install the un-lock warning switch assy.
2. Automatic Transaxle:

   Connect terminals 3 and 4 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 15: Installing UnLock Warning Switch Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Manual Transaxle:

   Secure the unlock warning switch assy wire harness to the steering column upper bracket assy with a new clamp as shown in the illustration.

   NOTE: Do not overtighten the clamp when securing the wire harness as the wire harness could be cut.
   Fig 16: Securing Unlock Warning Switch Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Automatic Transaxle:

   Secure the unlock warning switch assy wire harness to the steering column upper bracket assy as shown in the illustration.

   Fig 17: Securing Unlock Warning Switch Assy

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1. Make sure the ignition switch lock cylinder assy is in the ACC position.
2. Install the ignition switch lock cylinder assy.

1. Check that the steering lock mechanism is activated when the key is removed.
2. Check that the steering lock mechanism is deactivated when the key is inserted and turned to the ACC position.

HINT:

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

1. Check that the steering column tube bearing rotates smoothly without looseness in the axial direction or any irregular noise.

HINT:

Replace the steering column assy if the bearing does not rotate as specified.

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.
3. Secure the steering column tube in a vise. Insert aluminum plates between the steering column tube and the vise to prevent damage.
   NOTE:

   • Do not apply excessive force to the steering column tube bracket when holding the steering column tube in a vise.
   • Do not drop the steering main shaft assy.
   Fig 18: Securing Steering Column Tube In A Vise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy.
   Fig 19: Installing New Steering Main Shaft Snap Ring (Outer Side)

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1. Hold the steering column tube in a vise between aluminum plates.
   NOTE: Do not apply excessive force to the steering column tube bracket when holding the steering column tube in a vise.
2. Install a new steering main shaft bearing to the steering column tube using SST and a hammer.
   1. SST 09612-2201 1

Fig 20: Installing Steering Main Shaft Bearing

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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 21: Tightening Tapered-Head Bolts Until Bolt Heads Break Off

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1. Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined.
2. Push on the transponder key amplifier and install it to the upper bracket.

Fig 22: Aligning Transponder Key Amplifier

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1. Align the matchmarks on the steering intermediate shaft assy No. 2 and the steering main shaft assy and install them with bolt.
   1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

Fig 23: Aligning Matchmarks On Steering Intermediate Shaft Assy

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1. Install the steering column assy with the 3 bolts.
   1. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 
2. Connect each connector and clamp the wire harness to the steering column assy bracket.

Fig 24: Installing Steering Column Assy With Bolts

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1. Align the matchmarks on the steering intermediate shaft assy No. 2 and the steering intermediate shaft and install them with bolt.
   1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

Fig 25: Aligning Matchmarks On Steering Intermediate Shaft Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the matchmarks on the steering wheel assy and the steering main shaft assy.
2. Install the steering wheel assy with the set nut.
   1. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)