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Steering Column: Service and Repair

WARNING:
^ SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY-PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS.

^ WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT.

NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.




REMOVAL
1. Disable the SRS.
2. Loosen the air bag assembly fixing bolts from behind the steering wheel assembly using a TORX� driver or equivalent until the air bag assembly can be released from steering wheel.




3. Disconnect the yellow 2-way connector located behind the air bag assembly and remove air bag assembly
4. Disconnect horn lead connector.
5. Remove the steering wheel attachment nut.




6. Apply a setting mark across the steering wheel and shaft so parts can be reassembled in their original position.




7. Move the tires to the straight ahead position before removing the steering wheel and removing wheel with J-29752.
8. Feed wiring though the wheel and remove wheel.
9. Remove the steering lower cover and engine hood opening lever.




10. Remove the driver knee bolster assembly.
11. Remove the steering column cover.
12. Remove air conditioning lower duct.
13. Disconnect the wiring harness connectors located at the base of steering column.

CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

14. Remove the combination switch assembly with SRS coil.

NOTE: SRS coil is a part of combination switch assembly which cannot be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.

15. Remove the snap ring.
16. Remove the cushion rubber.
17. Disconnect shift lock cable (A/T only).
18. Disconnect the starter switch harness connector
19. Remove steering lock cylinder assembly.

Steering Column - Removal:




20. Apply a setting mark across the universal joint and steering shaft to reassemble the parts in their original position.
21. Remove steering column assembly.

INSTALLATION
1. Install the steering column assembly and align the setting marks on the universal joint and steering shaft made during removal.
2. Tighten the steering column fixing bolts (dash panel side) to the specified torque.

Torque: 19 N.m (14 lb.ft.)

3. Tighten the steering column fixing bolts (Pedal bracket) to the specified torque.

Torque: 17 N.m (13 lb.ft.)

4. Tighten the universal joint to the specified torque.

Torque: 25 N.m (18 lb.ft.)

5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T).
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS coil.
10. Connect the wiring harness connector located on the base of steering column.

Steering Column - Installation:




11. Turn the SRS coil clockwise to full, return about 3 turns and align the neutral mark.

CAUTION: When turning the SRS coil clockwise to full, stop turning if resistance is felt. Further forced turning may damage the cable In the SRS coil.




12.Install steering column cover.

CAUTION: When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harness starter switch, combination switch and SRS coil may not catch wiring.

13. Install the steering wheel and align the setting marks.
14. Tighten the steering wheel fixing nut to the specified torque.

Torque: 34 N.m (25 lb.ft.)

15. Connect horn lead.
16. Connect air bag wiring harness connector.

NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinches.

Steering Column - Installation:




17. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure.

Torque: 8 N.m (69 lb.in)

CAUTION: Never use the air bag assembly from another vehicle use only the air bag assembly for Trooper.

18. Enable the SRS.
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