Assembly

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

1. Coat molybdenum disulfide lithium base grease.
2. Install main shaft, as follows:
a. Install a new bearing, thrust collar and compression spring to the main shaft.
b. Install the main shaft into the column upper tube.





c. Using Special Service Tool (SST) 09950 - 40010 (09957 - 04010, 09958-04010) or equivalents, to compress the compression spring.
d. Using a snap ring expander, install a new snap ring.
3. Install tilt memory bolt, as follows:
a. Install the square nut and tilt memory bolt.
b. Using a hexagon wrench, torque the tilt memory bolt.
Torque: 6.4 Nm (56 inch lbs.).





4. Select two tilt steering bolts. Select the bolt with the plain thread end when the column upper tube mark is 2, and the bolt with the hollow-tipped thread end when the mark is 1.

NOTICE: Select the bolt type to match each number marked in the squares on the upper tube.

5. Install column upper tube with main shaft, as follows:
a. Install the column upper tube with main shaft into the column lower tube.





b. Using a vise, press in the two tilt steering bolts.

NOTE: Make sure the upper tube turns smoothly.

6. Install tilt lever lock shaft, tilt lever assembly, tilt sub lever and tilt lever.
7. Install two tilt pawls, as follows:
a. Install the tilt pawl to the column upper tube.

NOTE: Install the pawl pin into the long hole of the tilt lever/ tilt sub lever.

b. Install the bolt through the tilt pawls and tilt lever assembly.
c. Temporarily install the washer and nut.
d. Tighten the tilt lever assembly set bolt.
Torque: 2.9 Nm (26 inch lbs.).
8. Engage and adjust two tilt pawls, as follows:
a. Engage the tilt sub lever side pawl to the center of the ratchet.





b. While turning the tilt lever side collar of the tilt pawl, completely engage the tilt lever side pawl to the ratchet.
c. Torque the nut.
Torque: 5.9 Nm (52 inch lbs.).
9. Select two pawl stoppers, as follows:
a. With the tilt pawl and ratchet engaged, install the pawl stopper.





b. Check that the alignment marks on the stopper and pawl align when the stopper is lightly rotated to the pawl side.








c. If the alignment marks do not align, select pawl stopper according to the table.
d. After selecting the stoppers, check that on both sides the pawl and ratchet are fully engaged.
10. Install two pawl stoppers.
11. Install two tilt lever retainers, as follows:
Tilt lever side:
a. Install a new E-ring.
b. Install and torque the nut to the tilt steering bolt.
Torque: 15 Nm (11 ft. lbs.)
Tilt sub lever side:
a. Install the collar to the tilt memory bolt.
b. Install the spacer and a new E-ring.
c. Install and torque the nut to the tilt steering bolt.
Torque: 15 Nm (11 ft. lbs.)





d. Using a hexagon wrench to hold the tilt memory bolt, and torque the nut.
Torque: 5.9 Nm (52 inch lbs.).
12. Install three tension springs.
13. Install compression spring, as follows:
a. Install the two bushings to the spring.
b. Install the spring and torx bolt.
c. Using a torx socket wrench, torque the bolt.
Torque: 7.8 Nm (69 inch lbs.).
14. Install two lock wedges to the breakaway bracket.

NOTICE: Make sure that no grease gets on the contact surface between the lock wedge and the column lower tube.

15. Install breakaway bracket, as follows:
a. Install the steering shaft thrust stopper.





b. Install the breakaway bracket to the main shaft.

NOTICE: Be careful that the spline part of the main shaft does not separate.

c. Using a snap ring expander, install a new snap ring to the main shaft.
d. Install the column tube stopper bolt.
Torque: 19 Nm (14 ft.lbs.).
16. Install telescopic lever lock bolt, as follows:
a. Pull the steering column tube away from the breakaway bracket and facing the body installation surface of the breakaway bracket upward, temporarily install the lock bolt.





b. Install a double nut on the lock bolt.
Torque to 16 Nm (12 ft. lbs.), loosen once, then torque again to 7.4 Nm (65 inch lbs.).
17. Install telescopic lever, as follows:
a. Install the compression spring and ball.
b. Install the washer, lever, collar and bolt.
Torque: 25 Nm (19 ft. lbs.).
18. Install telescopic lever serrated attachment, as follows:
a. Rotate the telescopic lever until it touches the breakaway bracket.





b. Install the serrated attachment so that the alignment marks on the telescopic lever and the serrated attachment align.
c. Torque the nut.
Torque: 13 Nm (108 inch lbs.).
19. Install connector bracket. Torque the two bolts.
Torque: 4.9 Nm (43 inch lbs.).
20. Install protector. Tighten the two screws.
21. Install turn signal bracket. Tighten the two screws.





NOTE: Install the turn signal bracket so that its upper surface is parallel with upper surface of the capsule of the breakaway bracket.

22. Install column upper bracket, as follows:
a. Install the column upper bracket with two new tapered-head bolts.





b. Tighten the two tapered-head bolts until the bolt heads break off.
23. Install lower dust cover, as follows:





a. Using a press and wooden plate, install the dust seal.

NOTICE: Make sure to install the dust seal facing the correct direction.

b. Install the lower dust cover and clip.
24. Install sliding yoke, as follows:
a. Align the matchmarks on the sliding yoke and main shaft.
b. Torque the bolt.
Torque: 35 Nm (26 ft. lbs.).
25. Install ignition key cylinder illumination.
26. Check tilt operation, as follows:
a. Check that there is not axial play at the end of the main shaft.
b. With the main shaft in the neutral position, push the tilt lever and check that the main shaft rises to the uppermost position.
c. Lower the main shaft, and check that it locks in the uppermost position.
27. Check telescopic operation, as follows:
a. Check that there is no axial play when the lever is turned fully counterclockwise.
b. Check that the main shaft moves smoothly when the lever is turned clockwise.