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Tilt Steering Column: Reassembly

NOTE: When using a vise, do not overtighten it. 
  1. COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See  COMPONENTS  ) 
  2. INSTALL BUSHING 
    1. Coat a new bushing with molybdenum disulfide lithium base grease.
    2. Using SST and a hammer, tap in the bushing.
    1. SST 09612-2201 1
    Fig 1: Installing Bushing
    G02904199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TILT STEERING PAWL 
    1. Install a new pin to the pawl.
    2. Install the pawl to the column upper tube.
    3. Using a plastic hammer, tap in a new tilt steering No. 2 shaft.
    NOTE: Tap the shaft completely into the steering column upper tube. 
    Fig 2: Tapping Tilt Steering No. 2 Shaft
    G02904200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TURN SIGNAL BRACKET 

    Install the turn signal bracket with the 2 bolts.

  5. INSTALL MAIN SHAFT ASSEMBLY 
    1. Install the bearing thrust collar and compression spring to the shaft.
    2. Install the shaft assembly to the column upper tube.
    3. Using SST, compress the compression spring.
      1. SST 09950-4001 1 (09958-04011)
      NOTE: Do not bend the universal joint of the shaft more than 20° 
    4. Using a snap ring expander, install a new snap ring to the shaft.
  6. INSTALL TILT LEVER RETAINER 
  7. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY 
    1. Install the column upper tube with the main shaft to the column tube.
    2. Using a hexagon wrench, torque the 2 tilt steering bolts.
      1. Torque: 20 N.m (210 kfg.cm, 15 ft.lbf) 
    3. Check that the upper tube turns smoothly.
  8. INSTALL TILT LEVER LINK 
    Fig 3: Compressing Compression Spring
    G02904201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL TILT LEVER 
    1. Install the 2 bushings and tilt lever to the column upper tube, as shown in Fig 4 .
    2. Install a new spring nut to the lever.
  10. INSTALL 4 TENSION SPRINGS 

    HINT:

    Install the springs with the tilt function at maximum tilt up.

    Fig 4: Installing Spring Nut To Lever
    G02904202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL 2 ENERGY ABSORBING PLATES 
    1. Install the 2 new energy absorbing guides and 2 new absorbing plates.
    2. Install the 2 new energy absorbing clips.
  12. INSTALL COLUMN TUBE SUPPORT 

    Install the tube attachment with the bolt to the column tube support.

    1. Torque: 15 N.m (150 kfg.cm, 11 ft.lbf) 
    Fig 5: Locating 2 Energy Absorbing Plates
    G02904203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP 
    1. Install the column upper bracket and column upper clamp with 2 new tapered-head bolts.
    2. Tighten the 2 new tapered-head bolts until the bolt heads break off.
  14. INSTALL TRANSPONDER KEY AMPLIFIER ASSEMBLY 
    Fig 6: Locating Tapered-Head Bolts
    G02904204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL INTERMEDIATE SHAFT ASSEMBLY 
    1. Install the thrust stopper and upper side No. 2 lower cover.
    2. Align the matchmarks on the intermediate shaft assembly and main shaft assembly.
    3. Install the bolt.
    1. Torque: 34 N.m (350 kfg.cm, 25 ft.lbf) 
  16. INSTALL NO. 2 LOWER COVER 

    Install the No. 2 lower cover with the 2 nuts.

    1. Torque: 25 N.m (260 kfg.cm, 19 ft.lbf) 
    Fig 7: Aligning Matchmarks On Intermediate Shaft Assembly & Main Shaft Assembly
    G02904205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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