Disassembly/Assembly
Fig. 8 Steering column exploded view. Motor Home:
MOTOR HOME
Disassembly
1. Clamp column assembly in a vise.
2. Remove turn signal lever, then remove turn signal switch retaining screws and lift switch up and position aside.
3. Remove snap ring from upper end of steering shaft.
4. Remove the 3 bearing housing retaining screws. These screws must be removed before steering shaft is removed.
5. Install tool C-4044 or equivalent, and press shaft out of bearing, then remove bearing housing from shaft.
6. Remove bearing lower snap ring from shaft, then remove shaft through lower end of column.
7. Place ignition switch lock cylinder in Lock position and remove key. Insert a small screwdriver into lock cylinder release hole and push in to release spring loaded lock retainer. Pull out lock cylinder and remove ignition switch.
8. Remove the 4 lock housing-to-column jacket hex head retaining screws and remove both housing and spring washer from jacket.
Inspection
1. Clean all parts in suitable cleaning solvent and inspect parts.
2. Inspect turn signal switch for distortion or broken parts or damaged parts. Inspect wiring harness for worn or bare spots.
3. Inspect steering shaft bearing for smooth operation. If bearing shows any signs of roughness or wear, it should be replaced.
Reassembly
1. Install boot and floor plate on lower end of column jacket.
2. Install spring washer and both housings.
3. Position ignition switch in center detent (Off) position. Feed wires down through the space between housing and jacket. Position switch in housing and tighten the 3 retaining screws.
4. With ignition key cylinder in Lock position, remove key. Insert cylinder into housing, then press cylinder until contact is made with pin on ignition switch cam. Insert key into lock and rotate until slot in cylinder plate aligns with pin. Press cylinder in the remaining way, making sure retainer bar snaps into its slot in lock housing.
5. Insert steering shaft assembly into column, then install bearing lower snap ring on shaft.
6. Place rubber insulator with ground staple over column upper bearing and install assembly into housing bore. Use lubricant to ease installation.
7. Install turn signal switch, while feeding the wires through the opening in the housing, then install retaining plate and torque the 3 retaining screws to 27 inch lbs.
8. Install turn signal lever and torque retaining screw to 30 inch lbs.
9. Place bearing housing assembly on column jacket assembly, while feeding wires through space between lower housing and jacket. Install wire cover trough.
10. Using tool C-3879 or equivalent, washer and nut, install housing onto steering shaft. Remove tool and install snap ring.
11. Install the 3 bearing housing to lock housing screws and torque to 35 inch lbs.
Fig. 9 Non-tilt wheel steering column exploded view (column shift auto. trans.) Vans & Wagons exc. front wheel drive:
Fig. 10 Non-tilt wheel steering column exploded view (floor shift man. trans.) Vans & Wagons exc. front wheel drive:
Fig. 11 Non-tilt wheel steering column exploded view (column shift auto. trans.) Ramcharger, Trailduster & W/D-100 thru 400 series:
Fig. 12 Non-tilt wheel steering column exploded view (floor shift man. trans.) Ramcharger, Trailduster & W/D-100 thru 400 series:
EXCEPT MINI-VANS/WAGONS, MOTOR HOME, RAMPAGE & SCAMP
DISASSEMBLY
Shift Lever, Turn Signal Switch & Lamp Assembly
1. Pry out wiring trough retainers and lift off wiring trough.
2. Using a suitable punch, drive out shift lever roll pin. Use a deep socket to accept the roll pin as it is driven out.
3. Place steering column in a vise by securing it at the bracket.
4. Remove turn signal switch and upper bearing retaining screws, then remove retainer and lift switch up and out of the way.
5. Remove retaining screw and lift off ignition key lamp assembly up and out of the way.
Steering Shaft
1. Remove snap ring from upper end of steering shaft.
2. Remove 3 screws retaining bearing housing to lock housing. These screws must be removed before steering shaft is removed.
3. Remove bearing housing from shaft, and then the coil spring.
4. Remove lock plate from shaft, then remove shaft through lower end of column.
Lock Housing
1. If equipped with shift indicator dial, remove pointer screw and position pointer aside.
2. If equipped, remove screw and lift out buzzer switch.
3. Remove 2 retaining screws and lock lever guide plate to expose the lock cylinder release hole.
4. Place cylinder in "Lock" position and remove key. Insert a small screwdriver into lock cylinder release hole and push in to release spring loaded lock retainer, while pulling lock cylinder out of the housing.
5. Remove the 3 retaining screws and ignition switch assembly.
6. Grasp lock lever and spring assembly and pull straight out of housing.
7. Remove the four lock housing to column jacket hex retaining screws and remove housing from jacket.
Shift Tube
1. On Ramcharger, Trailduster and D/W-100 thru 400 series models with automatic transmission, loosen shift tube set screw in shift housing and remove shift tube through lower end of jacket.
2. On Van and Wagon models with automatic transmission, remove indicator bracket and then the shift tube through the lower end of the jacket.
3. On Van and Wagon models with manual transmission, remove the three bearing support screws at lower end of jacket and the three adjustable bushing screws from cam slots in jacket, then remove shift tube and lever assembly through lower end of jacket.
4. On all models, remove floor plate and grommet from jacket.
Fig. 13 Steering shaft flex coupling exploded view:
Steering Shaft Flex Coupling
1. Remove the 4 bolts and two cross straps.
2. Remove flex coupling.
3. Check coupling and cross straps for cracks, warpage or distortion. Replace as required.
4. Position flex coupling in the two cross straps, then install two long and short attaching bolts. Ensure that master spline on steering shaft lines up with master spline in lower pot coupling during assembly.
5. Torque coupling attaching bolts to 200 inch lbs.
Fig. 14 Steering shaft pot coupling exploded view:
Steering Shaft "Pot" Coupling
1. Pry cover tangs from coupling body and lift seal and cover from body.
2. Drive the small short dowel pin at edge of body coupling, down into coupling. A new dowel pin will be required during assembly.
3. Pull body off shaft and shoe assembly.
INSPECTION
1. Clean all parts in suitable solvent then inspect for wear or damage.
2. Inspect condition of shift lever gate and inner end of shift lever.
3. Inspect turn signal switch for distortion, broken or damaged parts.
4. Inspect steering shaft bearings for smooth operation. Replace bearing if it is rough or worn.
ASSEMBLY
During assembly, apply a thin coat of NLGI grade E.P. 2 or equivalent grease to all friction surfaces.
1. Clamp column in a vise so that both ends are accessible.
2. Check column tube-to-mandrel rivets for tightness. If loose, replace using 1/8 inch diameter by 1/4 inch long (1/8 inch grip) rivets. When replacing rivets, make sure to use ones of the same type material as removed.
3. Install floor plate and grommet on lower end of column jacket.
4. On automatic transmission columns:
a. Place gearshift housing on column jacket, then with dust seal and shift tube support installed on shift tube, slide assembly into jacket. Guide key on upper end of tube into slot in gearshift housing.
b. Position crossover load spring and shift lever in gearshift housing and tap the pivot pin into place.
c. Install shift lever gate on lock housing.
d. If used, feed gear selector dial lamp wire through hole behind transmission dial on lock housing and route wire down through space between housing and jacket. Secure lamp assembly to rear of dial with 2 screws and install lens.
e. With shift lever in mid-position, seat lock housing on top of jacket, indexing key in housing with slot in jacket. Install and alternately tighten all 4 screws to insure proper seating of housing, then torque to 90 inch lbs.
f. Install indicator bracket.
5. Grease and assemble the two lock levers, lock lever spring and pin, then install assembly in housing. Seat pin firmly into bottom of slots, making sure that lock lever spring leg is firmly in place in lock casting notch.
6. Install lock lever guide plate and retaining screws.
7. Position ignition switch to center detent (Off) position and shift lever in Park (Reverse for manual transmission columns). Feed wires down through space between housing and jacket, then position switch in housing and tighten the 3 retaining screws.
8. To install ignition lock, turn ignition lock to "Lock" position and remove key. The cylinder will move inward and a spring loaded retainer will snap into place, locking the cylinder to the housing.
Fig. 14 Steering shaft pot coupling exploded view:
9. To assemble steering shaft "Pot" coupling:
a. Fill coupling body about 1/2 full with NLGI grade 2 E.P. or equivalent grease.
b. Place cover and seal on shaft.
c. Press shoe pin into steering shaft so that it projects an equal mount on each side of shaft.
d. Place spring on side of shaft and over the shoe pin, then place shoes on pin ends with flat side toward spring, engaging tangs.
e. Squeeze shoes together to compress spring and push assembly into coupling. Align master spline mark of coupling body with master spline on upper shaft.
f. Drive in a new roll pin until flush with outer surface of coupling body.
g. Position seal and cover on body and crimp cover tangs securely over projections on body.
h. Move shaft in and out several times to distribute lubricant.
10. Install bearing support (floor shift), bearing and spring on steering shaft and insert the steering shaft assembly into the column.
11. Install steering column shaft lock plate sleeve over shaft lock plate pin. Do not hammer column shaft lock plate sleeve, as damage to the telescoping shaft may result.
12. Install coil spring or bearing lower snap ring.
13. Install ignition key lamp assembly into bearing housing.
14. Place rubber insulator with grounding staple over column upper bearing and install assembly into bearing housing bore. Use lubricant to ease installation.
15. Install turn signal switch into bearing housing, while feeding the wires through opening in housing. Also feed the ignition key lamp wires through the opening.
16. Install retaining plate over the switch and torque the retaining screws to 27 - 30 inch lbs.
17. Install turn signal lever. If equipped with speed control, feed wires through opening provided in the bearing housing.
18. Place bearing housing assembly on steering shaft, while feeding the wires through the opening between lower housings and jacket.
19. Install bearing on steering shaft. Do not hammer shaft into the bearing or bearing onto shaft as damage to steering column or shaft may result.
20. Install upper snap ring on shaft, then install and torque the 3 bearing housing to lock housing screws to 35 inch lbs.
21. Install wiring trough in place over wires, being careful not to pinch wires between trough and jacket.