Coupling
1. Use the procedures outlined in TechCONNECT Steering/Column/Removal/Column-Steering to remove the steering column from the vehicle.CAUTION:
When handling the steering column use care to avoid holding the column by any part of the tilt/telescope mechanism or by the shaft boot. The column should be held by its mounting bracket and the shaft by the exposed portions.
2. Place the steering column on a clean work bench.
3. Remove black and white wiring connectors from the connector bracket by lifting the pin located in the middle of the connectors and sliding the connectors backwards off the connector bracket.
4. Remove the black plastic connector support from the column mounting bracket and discard.
5. Remove jacket bolt from the upper tilt gear assembly (Fig. 3).
6. Remove bushings from tilt gear.
CAUTION:
Avoid turning the gear while disassembling the tilt gear assembly throughout the Repair Procedure.
7. Lift column jacket. Secure column jacket from falling down and remove the bolts attaching the electric tilt gear drive motor.
8. Slide the motor toward the rear of the column and remove the motor.
9. Remove the coupler from tilt gear assembly.
10. Install the replacement coupler, p/n 05183374AA on the tilt gear assembly.
11. Install the tilt drive motor, torque the bolts to 4 Nm (36 in. lbs.).
12. Install the replacement connector support, p/n 05183384AA, (Fig. 5).
13. Install black wiring connector in the upper support position. Install white connector in the lower support position. Ensure retaining connector clips are engaged.
14. Ensure the chamber in the mounting holes in the tilt gear assembly for the jacket bolt face (outboard) away from the column jacket prior to column jacket installation.
15. Lower the steering column jacket into the installed position.
16. Install two new bushings, p/n 05183376AA, in tilt gear assembly.
17. Install new jacket bolt, p/n 05183375AA, and new jacket bolt nut, p/n 05183377AA, so the nut is on the left side of the column when the column is installed in the vehicle. Ensure the bushings are seated properly.
CAUTION:
Turn the nut only. Hold the bolt in position.
18. Tighten the nut to 8 Nm (71 in. lbs.). Loosen the nut 180 degrees. Tighten the nut to 4 Nm (36 in. lbs.).
NOTE:
Steps 19 and 20 apply to vehicles built prior to June 1, 2004.
19. Remove the steering column brace bracket from the cross-car beam and discard.
20. Install the revised steering column brace bracket, p/n 04595995AA, to the cross-car beam. Torque the fasteners to 2.8 Nm (25 in. lbs.).
CAUTION:
All fasteners must be torqued to specification to ensure proper operation of the steering column.
21. Position the steering column on the instrument panel and loosely install the upper mounting screws.
22. Firmly slide the steering column upward against the instrument panel and loosely install the pivot bolt and nut.
23. Tighten the steering column upper mounting bolts to 30 Nm (22 ft. lbs.).
24. Tighten the pivot bolt (2) to 30 Nm (22 ft. lbs.).
25. Center the two retaining nuts at the bulkhead for the steering column boot and tighten mounting nuts to 7 Nm (62 in. lbs.).
26. Raise and support vehicle.
27. Check and make sure plastic collar on column shaft is engaged in groove within boot, (Fig. 6).
28. Slide the steering shaft into the lower coupling so the pin on the steering shaft on the opposite side from the slot in the lower coupling. If the pinch bolt hole does not align remove the steering shaft from the lower coupling, rotate it 1800 and reinsert it into the coupling.
29. Install a NEW pinch bolt, p/n 06507656AA. Tighten the pinch bolt to 31 Nm (23 ft. lbs.).
30. Lower the vehicle.
31. Install the instrument cluster, refer to TechCONNECT 8 - ELECTRICAL/INSTRUMENT CLUSTER - INSTALLATION.
32. Attach the pigtail for the Steering Column Control Module (SCCM) to the steering column SCCM connector support bracket.
33. Plug in the steering column tilt and telescope wiring connectors.
34. Position the roll top shroud (1) and install the mounting screws.
35. Install the SCCM assembly (1) onto the steering column.
36. Tighten the set screw securing the SCCM assembly.
37. Tighten clockspring screws that were backed out to keep the clockspring from unwinding, refer to TechCONNECT 8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING - REMOVAL.
38. Align the spline on the steering wheel hub to shaft and install the steering wheel.
39. Install the retainer bolt and torque it to 70 Nm (52 ft. lbs.).
40. Install the airbag, refer to TechCONNECT 8 - ELECTRICAL/RESTRAINTS/DRIVER AIRBAG - INSTALLATION.
41. Install the negative battery terminal on the battery. It is important that this is performed properly (including calibration of steering angle sensor if equipped with Electronic Stability Program (ESP)), refer to TechCONNECT 8 - ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE).
NOTE:
A revised steering column brace, p/n 04595994AA, is required for vehicles built prior to June 1, 2004, vehicle built on or after June 1, 22004 use the originally installed brace.
42. Use the power tilt/telescope switch to position the steering column in mid-tilt position prior to attaching the revised steering column brace, p/n 04595994AA, (Fig. 7).
NOTE:
The slotted end of the brace attaches to the brace bracket with the notched out portion of the brace facing toward the front of the vehicle, (Fig. 8).
43. Install the bolts fastening the steering column brace to the steering column and brace bracket. Use bolt, p/n 06507224AA, to attach the slotted end of the brace to the bracket. First, tighten the mounting bolt at the column to 30 Nm (22 ft. lbs.). Then, tighten mounting bolt at the bracket to 11.3 Nm (100 in. lbs.).
44. Install the steering column opening reinforcement.
45. Install the steering column opening cover.
46. Test the operation of the horn, lights and any other functions that are steering column operated.
47. Verify column is functional in tilt and telescope. No binding or noise must be present. If full travel is not achieved use the StarSCAN(R) to run the column to the full up position, the column should now achieve full travel.
48. Set the clock to the correct time.