Steering column assembly. 1 - steering column, 2 - upper steering column cover, 3 - steering wheel, 4 - horn cover, 5 - combination switch, 6 - air duct, 7 - intermediate shaft.
Steering column (option without tilt angle adjustment). 1 - steering column hatch cover, 2 - sealing ring, 3 - lower bearing, 4 - retaining ring, 5 - steering column tube, 6 - shear head bolt, 7 - ignition switch bracket, 8 - main shaft, 9 - retaining ring, 10 - clamp, 11 - lower bracket.
Steering column (variant with adjustable tilt angle). 1 - retaining ring, 2 - steering column hatch cover, 3 - sealing ring, 4 - steering column tube holder, 5 - steering column tube, 6 - bushing, 7 - shear head bolt, 8 - steering column mounting bracket, 9 - retaining ring, 10 - lower bearing, 11 - boot, 12 - retaining ring, 13 - ignition switch bracket, 14 - upper bearing, 15 - main shaft, 16 - intermediate shaft, 17 - tilt adjustment bracket, 18 - bushing No.1, 19 - adjustment lever, 20 - pin, 21 - adjustment lever mounting bracket, 22 - bushing, 23 - pawl, 24 - tension spring, 25 - steering column mounting bracket, 26 - tension spring with cable, 27 - bracket stopper, 28 - bushing No.2, 29 - lever travel limiter.
Removal
1. Removing the steering wheel.
a) Remove the signal cover and unscrew the nut.
b) Apply timing marks to the steering wheel and main shaft assembly.
c) Using a puller, remove the steering wheel.
2. Removing the lower universal joint,
a) Apply timing marks to the intermediate shaft and the cardan joint fork.
b) Disconnect the cardan joint and the intermediate shaft.
Disassembly
Note: For the version without tilt angle adjustment, the removal of the corresponding parts is carried out in the same way.
1. Removing the tension springs and cables.
a) Tilt the main shaft fully.
b) Using a screwdriver, remove the spring and cable.
2. Removing the intermediate shaft.
a) Apply timing marks to the intermediate shaft and the cardan joint fork.
b) Loosen the intermediate shaft mounting bolt on the cardan joint.
c) Remove the retaining ring.
d) Disconnect the intermediate shaft from the main shaft.
3. Loosen the bolts and remove the steering column mounting pipe from the steering column mounting bracket.
4. Removing the ignition lock cylinder.
a) Set the ignition key to the "ACC" position.
b) Press the lock with a thin rod and remove the ignition lock cylinder.
5. Removing the ignition switch bracket and main shaft.
a) Unscrew the two bolts and remove the stiffener.
b) Using a chisel and hammer, loosen the shear head bolt.
c) Unscrew the three bolts and disconnect the ignition switch bracket from the steering column mounting bracket.
6. Remove the ignition switch.
7. Removing the main shaft from the ignition switch bracket.
a) Using the special tool, compress the main shaft and ignition switch bracket.
b) Using pliers, remove the retaining ring.
c) Loosen the special tool and remove the main shaft, spring and bushing from the ignition switch bracket.
8. Removing the tilt adjustment bracket from the steering column mounting bracket.
a) Remove the tension spring.
b) Unscrew the two nuts and bolt, remove the adjustment lever mounting bracket and remove the bushing.
c) Remove the pin
d) Remove the dog
d) Unscrew the pawl mounting bolt.
d) Unscrew the nut and remove the bolt with the bracket stopper.
e) Loosen the tilt angle adjustment lever mounting nut.
g) Temporarily screw a flat nut onto the bolt and tap it with a plastic hammer.
c) Remove the nut, then remove the bushing and the lever travel limiter.
i) Unscrew the mounting bolt, remove the nut and sleeve.
Examination
1. Replacing the bearing in the ignition switch bracket (if necessary).
a) Using a special tool and a hammer, remove the bearing.
b) Apply grease to the bearing.
c) Using a special tool and a hammer, press the bearing into the ignition switch bracket.
2. Replace the lower bearing if necessary.
a) Using the special tool and a press, remove the lower bearing from the main shaft.
b) Apply grease to the bearing.
c) Using a special tool and a press, press the lower bearing onto the main shaft.
3. Replace the intermediate shaft bearing if necessary.
a) Using pliers, remove the retaining ring.
b) Remove the bearing from the intermediate shaft.
c) Press in the new bearing.
d) Using pliers, install the snap ring.
4. Replacing the crosspiece (if necessary).
a) Remove the four retaining rings.
b) Using tool heads (12 and 22 mm) and a vice, press the bearing out of the joint crosspiece.
c) Clamp the bearing in a vice and use light hammer blows to separate it from the crosspiece.
Note: Removal of the remaining bearings is similar.
d) Apply lithium based grease with molybdenum disulfide to the bearings and crosspiece.
Caution: Do not apply too much lubricant.
d) Using a tool head (12 mm) and a vice, press in the bearing.
e) Using a tool head (10 and 12 mm) and a vice, adjust the position of the bearings so that the distance from each bearing to the edge of the fork is as large as possible and the same.
g) Select two retaining rings of the same thickness so that the axial clearance is within 0.00 - 0.05 mm.
Caution: Do not reuse snap rings.
| Label | Thickness, mm |
| No tag | 1,175- 1,225 |
| Brown | 1,225- 1,275 |
| Blue | 1,275- 1,325 |
Assembly
1. Apply consistent lubricant to the friction surfaces of the parts.
2. Install the pawl mounting bolt.
Tightening torque - 18 Nm
3. Installing the adjustment lever on the bracket.
a) Select bushing No.1 according to the table to eliminate play.
b) Install the adjustment lever and sleeve No.1 on the bracket.
c) Select bushing No.2 according to the table to eliminate play.
d) Install bushing No.2 into the bracket.
d) Drive the special bolt into the tilt angle adjustment bracket.
e) Install the pawl.
g) Install the tension spring and pin.
c) Install the bushing and the adjustment lever mounting bracket.
Tightening torque - 18 Nm
4. Installing the lever travel limiter,
a) Using the table provided, select the lever travel limiter.
| Label | Thickness, mm |
| No tag | 0,197-0,203 |
| 5 | 0.495 - 0,505 |
| 8 | 0,795 - 0,805 |
| 14 | 1,395- 1,405 |
| 18 | 1,795-1,805 |
b) Install the lever travel limiter, bolt, washer and locknut.
Tightening torque - 18 Nm
5. Installing the bracket stop bolt.
a) Install the stopper bolt, bracket stopper, washer and tighten the lock nut as shown in the figure.
b) Tighten the nut while holding the bracket stopper as shown in the figure.
Tightening torque - 10 Nm
6. Assembling the main shaft and ignition switch bracket.
a) Assemble the bushing, spring and main shaft, and insert into the ignition switch bracket.
b) Using the special tool, compress the main shaft with the bracket and install the retaining ring.
Note: Do not tighten the special tool too much.
7. Assembling the tilt angle adjustment bracket and ignition switch bracket.
a) Apply sealant to one or two threads of the bolt.
Sealant: Three Bond 1324 or equivalent.
Note: This sealant is not air-drying. Apply hardener only when the sealant is evenly coated on the bolt threads without cavities.
b) Install two mounting bolts, (one of the bolts with a clamp for fastening the wiring).
The text is taken from the specified website (www.toyotaman.ru)
Tightening torque: 7.4 Nm
c) Install the shear head bolt and tighten it until the head shears off.
d) Install the stiffener and tighten the two mounting bolts.
8. Install the steering column mounting bracket onto the column tube.
Tightening torque - 18 Nm
9. Install the holder and new sealing ring onto the steering column tube, and then install the steering column cover.
10. Installing the intermediate shaft.
a) Align the timing marks on the main shaft cardan joint yoke and the intermediate shaft, and tighten the mounting bolt.
Tightening torque - 25 Nm
Note: Be careful not to push out the oil seal when installing the intermediate shaft.
b) Secure the steering column tube with a retaining ring.
11. Install the tension springs and cables.
12. Checking the operation of the tilt angle adjustment lever and bracket.
a) Make sure that the end of the main shaft is not subject to play.
b) Make sure the main shaft is securely locked in all six positions.
13. Installing the ignition switch.
a) Set the ignition switch key to the "ACC" position, then install the ignition switch cylinder into the ignition switch bracket.
6) Install the ignition switch.