Assembly
Fig. 27 Shift tube installation. Except front wheel drive Mini-Vans/Wagons:
During assembly, lubricate all friction surfaces with NLGI grade 2 E.P. or equivalent grease.
1. Install bearing in housing, if removed.
2. Install lock shoe springs, lock shoes and shoe in bearing housing. Use a 0.180 inch rod to align shoes for pin installation. With tilt lever opening on left side and shoes facing up, the four slot shoe is on the left.
3. Install spring, release lever and pin in bearing housing. Relieve load on release lever as described in step 30 in the "Disassembly" procedure.
4. Install drive shaft in housing, then lightly tap sector onto shaft just enough to allow snap ring installation.
5. Install lock bolt and engage with sector cam surface.
6. Install rack and spring. Block tooth on rack to engage block tooth on sector, then install external tilt release lever.
7. Install bolt spring and spring retaining screw and torque to 35 inch lbs.
8. Install shift lever spring in bowl by winding up with pliers and pushing in. Slide bowl into jacket.
9. Install wave washer and lock plate into position, then work lock plate into notches in jacket by tipping lock plate toward bowl at 12 o'clock position and under jacket opening. Slide lock plate into notches in jacket.
10. Carefully install shift tube in lower end of jacket. Align key in tube with keyway in bowl and use tool C-4119 or equivalent to pull shift tube into bowl. Install thrust washer and retaining ring by pulling bowl up to compress wave washer. Do not push or tap end of shift tube.
11. Install support by aligning "V" in support with "V" notch in jacket. Install screws through support into lock plate and torque to 60 inch lbs.
12. If removed, install lower bearing in lower end of shift tube. Locate it about 3/16 inch inside of tube and use lubricant to ease installation.
13. Install centering spheres and anti-lash spring in upper steering shaft, then install lower steering shaft from same side of spheres that spring ends protrude. Check fit of double coupling assembly to assure that master serration of upper shaft aligns with master serration of pot coupling.
14. Place housing in full up position and install guide, tilt spring, and tilt spring retainer using a screwdriver in retainer slot. Turn retainer clockwise to engage.
15. Install steering shaft assembly in shift tube upper end.
16. Install ignition switch and actuator rod through bowl from bottom and insert support slot. Extend rack downward from bearing housing, then assemble bearing housing over steering shaft and engage rack over end of actuator rod.
17. Install external tilt release lever, then while holding lock shoes in disengaged position, assemble bearing housing over steering shaft until pivot pin holes align and install pivot pins.
18. Place housing in full up position, then install guide plate after making sure there is grease between the guide and peg on support, tilt spring and tilt spring retainer. Using a screwdriver, turn retainer clockwise to engage.
19. Install bearing inner race and seat, then install tilt release lever shield.
20. Remove tilt release lever, then install housing cover and torque retaining screws to 100 inch lbs.
21. If used, assemble buzzer switch to spring clips with formed end of clips under end of switch and spring bowed away from switch on side opposite contact. Push spring into hole in cover to the step with contacts toward the lock cylinder bore. Install combination switch onto steering column. Connect electrical connectors onto combination switch.
22. Insert turn signal switch wires and connector through cover, bearing housing and bowl. Push hazard warning plunger in, install switch and tighten screws to 25 inch lbs.
23. Install hazard warning knob and pull out, then install cancelling spring, cancelling cam and shift lock plate.
24. Using tool C-4156 or equivalent, depress shift lock plate and install a new snap ring.
25. Install tilt release lever and turn signal switch lever.
26. On models with a key warning buzzer, turn ignition lock to Lock position and remove key. This will cause buzzer operating lever to retract in cylinder. Insert cylinder into housing far enough to contact switch actuator. Press in and move switch actuator rod up and down to align parts. When parts align, the cylinder will move inward allowing a spring loaded retainer to snap into place, locking the cylinder to the housing.
27. On vehicles without a key warning buzzer, turn ignition lock to Lock position and remove key. Insert cylinder into housing far enough to contact switch actuator. Press inward and move switch actuator rod up and down to align parts. When parts align, the cylinder will move inward allowing spring loaded retainer to snap into place, locking the cylinder to the housing.
28. To install ignition switch, position key cylinder in Accessory detent (full counterclockwise and then to the extreme other end).
29. Slide rod into slider hole and assemble loosely to column with two screws. Lightly push the switch down the column to remove lash from actuator rod and torque retaining screws to 35 inch lbs.
30. Install wire protector over wires on column using care to avoid pinching wires.
31. Remove column holding fixture, then install bracket to column and torque bolts to 120 inch lbs.
32. Align master splines and install coupling assembly and roll pin on steering shaft.