Assembly

ASSEMBLY

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





1. Coat with 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. Use Special Service Tool (SST) 09950 - 40010 (09958 - 04010) or equivalents, to compress the compression spring.
d. Using a snap ring expander, install a new snap ring.
3. Install tilt steering housing support.
Torque: 13 Nm (9 ft. lbs.).
4. Install column upper tube with main shaft, as follows:
a. Install the column upper tube with main shaft into the tilt steering housing support.
b. Using a snap ring expander, install a new snap ring to the main shaft.





c. Using a vise, press in the two tilt steering No. 1 bolts with bushings.

NOTE: Make sure the column upper tube turns smoothly.

5. Install tilt steering gear assembly with motor, as follows:
a. Install the two bushings and support the stopper bolts to the tilt steering gear assembly with motor.





b. Using a vise, press in the two tilt steering No. 2 bolts.
c. Install the bond cable and spacer to the stopper bolt.
d. Install the spring to each stopper bolt.
e. Install and torque two new lock nuts.
Torque: 3.0 Nm (27 inch lbs.).
f. Tighten the bond cable set screw.
6. 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.
7. Install connector bracket. Torque the two bolts.
Torque: 4.9 Nm (43 inch lbs.)
8. Install No. 1 protector and No. 2 protector. Tighten the four bolts.





9. Install turn signal bracket. Install the turn signal bracket so that its upper surface is parallel with upper surface of the capsule of the breakaway bracket.
10. Install tilt position sensor. Tighten the screw.
11. Install telescopic position sensor, as follows:
a. Tighten the two screws.
b. Connect the connector.
12. Install telescopic sensor plate, as follows:





a. Install the sensor plate, as shown in the illustration.
b. Torque the bolt.
Torque: 4.9 Nm (43 inch lbs.).
13. 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.
14. 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.).
15. Install ignition key cylinder illumination. Tighten the screw.