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Friday, March 4, 2011

how to replace the ignition cylinder housing on 2005 chevy suburban

Removal & Installation



  1. Disable the SIR system. Refer to the Chassis Electrical Section.
  2. Remove the knee bolster.
  3. Remove the steering column trim covers from the steering column.
  4. Disconnect the steering column electrical connectors.
  5. Remove the wire harness assembly from the steering column and the wire harness strap.
  6. Slide the 2 connectors of the turn signal and multifunction switch assembly out of the bulkhead connector.
  7. Remove the key alarm connector (1) from the lock module assembly (2) in the following way:
    1. Rotate the key alarm connector (1) 90 degrees.
    2. Pull the key alarm connector (1) out of the lock module assembly (2).

      Click image to see an enlarged view

      Fig. Remove the key alarm connector (1) from the lock module assembly (2)


  8. Remove the passkey connector from the lock module assembly (2).
  9. Remove the connector (2) from the electric park lock (1), for vehicles equipped with floor shifters.

    Click image to see an enlarged view

    Fig. Remove the connector (2) from the electric park lock (1)-for vehicles with floor shifters

  10. Remove the ignition switch from the lock module using the J 42759.

To install:

  1. Install the ignition switch to the lock module.
  2. Install the key alarm connector into the lock module assembly.
    1. Push the key alarm connector into the lock module assembly.
    2. Rotate the key alarm connector 90 degrees so that the key alarm connector locks into place.

  3. Install the passkey connector into the lock module assembly.
  4. Install the connector (2) to the electric park lock (1) for vehicles equipped with floor shifters.

    Click image to see an enlarged view

    Fig. Connect the connector (2) from the electric park lock (1)-for vehicles with floor shifters

  5. Slide the 2 connectors of the turn signal and multifunction switch into the bulkhead connector.
  6. Attach the wire harness assembly to the steering column wire harness strap.
  7. Connect the steering column electrical connectors to the vehicle.
  8. Install the trim covers to the column.
  9. Install the knee bolster.
  10. Enable the SIR system.
    NOTE
    It may be necessary to reprogram the theft deterrent system if the module was replaced.



CAUTION
When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

  1. Disconnect the battery negative cable.
  2. Disable the SIR system, as outlined in the Chassis Electrical Section.
  3. Position the steering wheel half way between the upper and lower tilt stops.
  4. Remove the steering wheel.
  5. Roll back the shift lever seal from the upper and the lower shrouds.
  6. Remove the 2 TORX® screws from the lower steering column shroud.
  7. Remove the lower steering column shroud.
  8. Remove the 2 TORX® screws from the upper steering column shroud.
  9. Lift the upper steering column shroud to gain access to the lock cylinder access hole.

    Click image to see an enlarged view

    Fig. Using a bent tip awl, insert the tip into the ignition lock cylinder access hole.

  10. Turn the ignition lock cylinder to the START position. Using the bent tip awl, push down on the ignition lock cylinder retaining pin.
  11. Release the ignition lock cylinder to the RUN position.
  12. Remove the ignition lock cylinder from the lock module assembly by pulling the ignition lock cylinder away from the steering column.

    Click image to see an enlarged view

    Fig. Removing ignition lock cylinder


To install:

  1. Insert the ignition lock cylinder through the upper shroud.
  2. Install the ignition lock cylinder to the lock module assembly by doing the following procedure:

    Align the positioning slot and locking tab slot on the lock module assembly to the positioning tab and locking tab on the ignition lock cylinder.
    Push the ignition lock cylinder into the lock module assembly until the locking tab locks against the locking tab slot.

  3. Install the 2 TORX® screws to the upper shroud and tighten to 53 inch lbs. (6 Nm).
  4. Install the lower shroud.
  5. Install the shift lever seal to the upper and the lower shrouds.
  6. Install the steering wheel.
  7. Enable the SIR system.
  8. Connect the battery negative cable.
  9. Perform the Passlock learn procedure.


CAUTION
When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

  1. Disable the SIR system, as outlined in the Chassis Electrical Section.
  2. Remove the knee bolster.
  3. Remove the steering column trim covers from the steering column.
  4. Disconnect the steering column electrical connectors.
  5. Remove the wire harness assembly from the steering column and the wire harness strap.
  6. Slide the 2 connectors of the turn signal and multifunction switch assembly out of the bulkhead connector.
  7. Remove the key alarm connector from the lock module assembly in the following way:
  8. Rotate the key alarm connector 90 degrees.
  9. Pull the key alarm connector out of the lock module assembly.
  10. Remove the passkey connector from the lock module assembly.
  11. Remove the connector from the electric park lock, for vehicles equipped with floor shifters.
  12. Remove the ignition switch from the lock module using tool J42759 or equivalent.

To install:

  1. Install the ignition switch to the lock module
  2. Install the key alarm connector into the lock module assembly.
  3. Push the key alarm connector into the lock module assembly.
  4. Rotate the key alarm connector 90 degrees so that the key alarm connector locks into place.
  5. Install the passkey connector into the lock module assembly.
  6. Install the connector to the electric park lock, for vehicles equipped with floor shifters.
  7. Slide the 2 connectors of the turn signal and multifunction switch into the bulkhead connector.
  8. Attach the wire harness assembly to the steering column wire harness strap.
  9. Connect the steering column electrical connectors to the vehicle.
  10. Install the trim covers to the column.
  11. Install the knee bolster.
  12. Enable the SIR system.
  13. It may be necessary to reprogram the theft deterrent system if the module was replaced.


CAUTION
When you are performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.

  1. Disconnect the negative battery cable.
  2. Disable the SIR system, as outlined in the Chassis Electrical Section.
  3. Lower the hush and knee bolster.
  4. Remove the steering column trim covers.
  5. With the key installed, turn the key to the RUN position.
  6. Install an Allen wrench into the hole on top of the lock cylinder housing. Push down on the Allen wrench to release the tab on the lock cylinder inside the lock cylinder housing.
  7. Slide the lock cylinder out of the lock cylinder housing.

To install:

  1. Install the key into the lock cylinder.
    NOTE
    The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN.

  2. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start position - allowing it to spring return into the RUN position.
  3. Align the lock cylinder and install into the lock cylinder housing.
  4. Install the steering column trim covers. .
  5. Install the hush and knee bolster.
  6. Enable the SIR system.
  7. Connect the negative battery cable.

Refer to the Ignition Switch procedure in this section for servicing the Ignition Lock Cylinder.


The ignition switch removal?

Removal & Installation




CAUTION
When performing service around the SIR system components or wiring, the SIR system MUST be disabled. Failure to do so could result in possible air bag deployment, personal injury or unneeded SIR system repairs.

  1. Disable the SIR system. Refer to the Chassis Electrical Section.
  2. Make sure the switch is in the OFF position.
  3. Remove the steering wheel as outlined in this section.
  4. Disconnect the tilt wheel lever by pulling it out.
  5. Remove the knee bolster and the Torx® head screws from the lower column cover.
  6. Lower the cover by tilting it down and then sliding it back to disengage the locking tabs.
  7. Remove the Torx® head screws from the upper column cover.
  8. Remove the steering column lock set and the upper cover.
  9. Disconnect the wiring harness straps from the steering column wiring harness.
  10. Remove the retainer from Connector Position Assurance (CPA) if equipped.
  11. Disengage the connector from the Brake Transmission Shift Interlock (BTSI) if equipped.
  12. Unplug the gray and black connectors from the bulkhead connector.
  13. Unfasten the Torx® head screws from the switch and remove the switch.

    Click image to see an enlarged view

    Fig. Exploded view of the multi-function switch-


To install:

Installation is the reverse of removal but please note the following important steps.

  1. Install the switch. Use a small blade screwdriver to compress the electrical contact and move the switch into position. The electrical contact must rest on the canceling cam assembly.
  2. Fasten the Torx® head screws on the switch. Tighten the screws to 53 inch. lbs. (6 Nm).
  3. Install the upper column cover and fasten the column bracket nuts. Tighten the nuts to 22 ft. lbs. (30 Nm).
  4. Install the knee bolster and the steering column cylinder lock. Tighten the column cover Torx® screws to 12 inch. lbs. (1.4 Nm).
  5. Install the lower column cover and tighten the Torx® screws 53 inch. lbs. (6 Nm).
  6. Make sure the switch is in the OFF position and install the steering wheel. Refer to this section for this procedure.
  7. Enable the SIR system (if equipped).


NOTE
The steering column must be removed from the vehicle to perform the following procedure.

  1. Disable the inflatable restraint steering wheel module. Refer to AIR BAG/SIR.
  2. Remove the upper and lower trim covers.
    NOTE
    The abrasion sleeve located on the steering column wire harness assembly must be reinstalled. Make note of what connector (electronic lock module assembly) is coming out of the middle of the abrasion sleeve for installation purposes.

  3. Remove the wire harness strap from the steering column and the wire harness assembly.
  4. Slide the 2 connectors of the turn signal and multifunction switch assembly out of the bulkhead connector.
  5. Rotate the key alarm connector 90 degrees.
  6. Pull the key alarm connector out of the electronic lock module assembly.
  7. Remove the passkey connector from the electronic lock module assembly.
  8. Insert tool J42759 or equivalent into the electronic lock module assembly and slide the ignition and key alarm switch assembly out.

    Click image to see an enlarged view

    Fig. Using tool J42759 to release ignition switch from lock module assembly.


To install:

  1. Insert tool J42759 into the electronic lock module assembly and slide the ignition and key alarm switch assembly into the lock module assembly.
  2. Push the key alarm connector into the electronic lock module assembly.
  3. Rotate the key alarm connector 90 degrees so that the key alarm connector locks into place.
  4. Install the passkey connector into the electronic lock module assembly.
  5. Slide the 2 connectors of the turn signal and multifunction switch assembly into the bulkhead connector.
    NOTE
    The abrasion sleeve must be installed back onto the steering column wire harness assembly. The electronic lock module assembly wires and connector must be hanging out of the middle of the abrasion sleeve.

  6. Attach the wire harness strap to the wire harness assembly and the steering column.
  7. Install the upper and lower trim covers.
  8. Enable the inflatable restraint steering wheel module.

  1. Disable the SIR system. Refer to AIR BAG/SIR.
  2. Remove the knee bolster.
  3. Remove the steering column trim covers from the steering column.
  4. Disconnect the steering column electrical connectors.
  5. Remove the wire harness assembly from the steering column and the wire harness strap.
  6. Slide the 2 connectors of the turn signal and multifunction switch assembly out of the bulkhead connector.
  7. Rotate the key alarm connector 90 degrees.
  8. Pull the key alarm connector out of the lock module assembly.
  9. Remove the passkey connector from the lock module assembly.
  10. Remove the connector from the electric park lock (vehicles equipped with floor shifters).

To install:

  1. Install the ignition switch to the lock module.
  2. Install the key alarm connector into the lock module assembly.
  3. Push the key alarm connector into the lock module assembly.
  4. Rotate the key alarm connector 90 degrees so that the key alarm connector locks into place.
  5. Install the passkey connector into the lock module assembly.
  6. Install the connector to the electric park lock (vehicles equipped with floor shifters).
  7. Slide the 2 connectors of the turn signal and multifunction switch into the bulkhead connector.
  8. Attach the wire harness assembly to the steering column wire harness strap.
  9. Connect the steering column electrical connectors to the vehicle.
  10. Install the trim covers to the column.
  11. Install the knee bolster.
  12. Enable the SIR system.

  1. Disconnect the negative battery cable.
  2. Disable the SIR system. Refer to AIR BAG/SIR.
  3. Remove the hush and knee bolster.
  4. Remove the steering column trim covers.
  5. With the key installed, turn the key to the RUN position.
  6. Install an Allen wrench into the hole on top of the lock cylinder housing. Push down on the Allen wrench to release the tab on the lock cylinder inside the lock cylinder housing.
  7. Slide the lock cylinder out of the lock cylinder housing.
  8. Disconnect the passlock and key buzzer from the lock cylinder housing.
  9. Insert tool J42759 or equivalent into the lock cylinder housing to release the tabs on the ignition switch.
  10. Pull the ignition switch out of the lock cylinder housing.
  11. Disconnect the connector from the ignition switch.

To install:


NOTE
: The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN.



Click image to see an enlarged view

Fig. Verify the alignment of the gear in the ignition switch. If gear is not in position shown, turn gear in ignition switch until you reach the correct position.


NOTE
In order to reach a stop while rotating the lock cylinder housing gear you MUST push and hold in the solenoid on the electric park lock.

  1. Use a screwdriver to rotate the lock cylinder housing gear counterclockwise until it hits a stop.
  2. Connect the connector to the ignition switch.
  3. Insert the ignition switch into the lock cylinder housing. The tabs on the ignition switch MUST be seated inside the lock cylinder housing for proper installation.

    Click image to see an enlarged view

    Fig. Tabs on ignition switch engage slots in lock cylinder housing.

  4. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the START position - allowing it to spring return into the RUN position.

    Click image to see an enlarged view

    Fig. Screwdriver does the trick on this job.

  5. Align the lock cylinder and install the lock cylinder into the lock cylinder housing.
  6. Connect the passlock and key buzzer into the lock housing.
  7. Install the steering column trim covers.
  8. Install the hush and knee bolster.
  9. Enable the SIR system.
  10. Connect the negative battery cable.


CAUTION
If you are performing service on or near the SIR components or the SIR wiring, disable the SIR system. Refer to Disabling the SIR System in AIR BAG/SIR.

  1. Disconnect the negative battery cable.
  2. Disable the SIR system. Refer to the Chassis Electrical Section.
  3. Remove the hush and knee bolster.
  4. Remove the steering column trim covers.
  5. With the key installed, turn the key to the RUN position on 2005-06 models. On 2007 models turn the key to the START position.
  6. Insert an Allen wrench into the hole on top of the lock cylinder housing. Push down on the Allen wrench to release the tab on the lock cylinder inside the lock cylinder housing.

    Click image to see an enlarged view

    Fig. Insert Allen wrench through hole, push down on tab and slide out the lock cylinder

  7. Slide the lock cylinder out of the lock cylinder housing.
  8. Disconnect the passlock and key buzzer from the lock cylinder housing.
  9. Insert J 42759 into the lock cylinder housing to release the tabs on the ignition switch.

    Click image to see an enlarged view

    Fig. Insert J 42759 into the lock cylinder housing to release the tabs on the ignition switch

  10. Pull the ignition switch out of the lock cylinder housing.
  11. Disconnect the connector from the ignition switch.

To install:


WARNING
The gears between the ignition switch and the lock cylinder housing must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition switch and the lock cylinder housing, which may result in a NO START or BATTERY DRAIN.

  1. Verify the alignment of the gear (1) in the ignition switch (2). If gear (1) is not in position shown, turn gear in ignition switch (2) until you reach the correct position.
    NOTE
    In order to reach a stop while rotating the lock cylinder housing gear you MUST push and hold in the solenoid on the electric park lock.



    Click image to see an enlarged view

    Fig. Verify the alignment of the gear (1) in the ignition switch (2)



    Click image to see an enlarged view

    Fig. In order to reach a stop while rotating the lock cylinder housing gear you MUST push and hold in the solenoid on the electric park lock

  2. Use a screwdriver to rotate the lock cylinder housing gear counterclockwise until it hits a stop.
  3. Connect the connector to the ignition switch.
  4. Insert the ignition switch into the lock cylinder housing. The tabs on the ignition switch MUST be seated inside the lock cylinder housing for proper installation.
  5. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the START position - allowing it to spring return into the RUN position.

    Click image to see an enlarged view

    Fig. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the START position - allowing it to spring return into the RUN position

  6. Align the lock cylinder and install the lock cylinder into the lock cylinder housing.
  7. Connect the passlock and key buzzer into the lock housing.
  8. Install the steering column trim covers.
  9. Install the hush and knee bolster.
  10. Enable the SIR system.
  11. Connect the negative battery cable.




First rack and pinion gear removal:------
  1. Remove or disconnect the following:

    Wheel assemblies
    Engine shield, if equipped
    Stabilizer shaft
    Power steering high and low pressure lines
    Coupler clamp bolt from the intermediate shaft
    Outer tie rod ends from steering knuckle
    Intermediate shaft from the rack and pinion assembly
    Rack and pinion assembly mounting nuts, washers and bolts
    Rack and pinion assembly from the vehicle

    Click image to see an enlarged view

    Fig. Rack and pinion steering gear-Silverado



To install:

  1. Install or connect the following:

    Rack and pinion assembly into the vehicle
    Rack and pinion assembly mounting bolts, washers and nuts. Tighten the nuts to 136 ft. lbs. (185 Nm).
    Intermediate shaft to the rack and pinion assembly
    Coupler clamp bolt to the intermediate shaft. Tighten the bolt to 33 ft. lbs. (45 Nm).
    Low pressure hose
    High pressure hose. Tighten the hoses to 20 ft. lbs. (27 Nm).
    Outer tie rod ends
    Engine protection shield, if equipped
    Stabilizer shaft
    Wheels

  2. Lower the vehicle.
  3. Fill and bleed the power steering system.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:

    Wheel assemblies

    Click image to see an enlarged view

    Fig. Rack and pinion gear-2000-01 models

    Engine shield, if equipped
    Stabilizer shaft
    Power steering high pressure line from the rack and pinion assembly
    Power steering low pressure line from the rack and pinion assembly
    Coupler clamp bolt from the intermediate shaft
    Intermediate shaft from the rack and pinion assembly
    Rack and pinion assembly mounting nuts, the washers and the bolts
    Rack and pinion assembly from the vehicle


To install:

  1. Install or connect the following:

    Rack and pinion assembly into the vehicle
    Rack and pinion assembly mounting bolts, the washers and the nuts. Tighten the nuts to 136 ft. lbs. (185 Nm).
    Intermediate shaft to the rack and pinion assembly. Install the coupler clamp bolt to the intermediate shaft. Tighten the coupler clamp bolt to 33 ft. lbs. (45 Nm).
    Power steering low pressure hose to the rack and pinion assembly
    Power steering high pressure hose to the rack and pinion assembly. Tighten the hoses to 28 ft. lbs. (27 Nm).
    Engine protection shield, if equipped
    Stabilizer shaft
    Wheels

  2. Lower the vehicle.
  3. Fill and bleed the power steering system.

  1. Raise the vehicle.
  2. Remove the shield.
  3. Place a drain pan below the steering gear.
  4. Remove the power steering hoses from the steering gear.
  5. Cap the ends of the hoses and the power steering gear in order to prevent any entrance of dirt.
  6. Disconnect the intermediate shaft from the steering gear.
  7. Remove the pitman arm to relay rod nut.
  8. Disconnect the pitman arm from the relay rod.
  9. Remove the bolts retaining the steering gear to the frame.
  10. Remove the steering gear from the vehicle.
  11. Remove the pitman arm-to-power steering gear retaining nut.
  12. Remove the pitman arm from the power steering gear.

To install:

  1. Install the pitman arm to the power steering gear.
  2. Install the pitman arm to power steering gear retaining nut and washer and tighten to 184 ft. lbs. (250 Nm).
  3. Install the steering gear to the frame and install the retaining bolts and tighten to 110 ft. lbs. (150 Nm).
  4. Install the pitman arm to the relay rod.
  5. Install the pitman arm to the relay rod nut and tighten to 46 ft. lbs. (62 Nm).
  6. Install the intermediate shaft to the steering gear and tighten the upper and pinch bolt to 35 ft. lbs. (47 Nm)
  7. Remove the caps or plugs from the steering gear and hoses.
  8. Install the hoses to the steering gear and tighten the fittings to 20 ft. lbs. (28 Nm).
  9. Install the engine protection shield, if equipped.
  10. Remove the safety stands.
  11. Lower the vehicle.
  12. Bleed the power steering system.

  1. Remove or disconnect the following:

    Wheel assemblies
    Engine shield, if equipped
    Stabilizer shaft
    Power steering high and low pressure lines
    Coupler clamp bolt from the intermediate shaft
    Outer tie rod ends from steering knuckle
    Intermediate shaft from the rack and pinion assembly
    Rack and pinion assembly mounting nuts, washers and bolts
    Rack and pinion assembly from the vehicle

    Click image to see an enlarged view

    Fig. Rack and pinion steering gear



To install:

  1. Install or connect the following:

    Rack and pinion assembly into the vehicle
    Rack and pinion assembly mounting bolts, washers and nuts. Tighten the nuts to 136 ft. lbs. (185 Nm).
    Intermediate shaft to the rack and pinion assembly
    Coupler clamp bolt to the intermediate shaft. Tighten the bolt to 33 ft. lbs. (45 Nm).
    Low pressure hose
    High pressure hose. Tighten the hoses to 20 ft. lbs. (27 Nm).
    Outer tie rod ends
    Engine protection shield, if equipped
    Stabilizer shaft
    Wheels

  2. Lower the vehicle.
  3. Fill and bleed the power steering system.

STEERING GEAR REMOVAL:---

hese vehicles use a conventional power steering gear with a recirculating ball system. All tubes, hoses and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Be sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Inspect the hoses with the wheels in the straight-ahead position. Then, turn the wheels fully to the left and right while observing the movement of the hoses. Correct any hose contact with other parts of the vehicle that could cause chafing or wear. Power steering hoses and pipes should not be twisted, kinked or tightly bent. The hoses should have sufficient natural curvature in the routing to absorb movement and hose shortening during vehicle operation.

Click image to see an enlarged view

Fig. 3 long bolts attach the power steering gear to the driver-s side frame rail

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Set the front wheels in the straight-ahead position.
  3. Place a drain pan under the steering gear and disconnect the fluid lines. Cap the openings to protect the system from contamination.
  4. Remove or disconnect the following:

    Negative battery cable
    Adapter and shield from the gear and flexible coupling
    Flexible coupling clamp and steering box input shaft, matchmark for reassemble
    Flexible coupling pinch bolt
    Pitman arm to the Pitman shaft, matchmark for reassemble
    Pitman shaft nut and lock washer
    Pitman arm from the shaft using the proper puller
    Steering gear to frame bolts
    Gear assembly


To install:

  1. Install or connect the following:
    NOTE
    Check that the relationship of the flexible coupling to the flange is 1 / 4 - 3 / 4 in. (6-19mm) of flat.



    Steering gear in position, guiding the input shaft into the flexible coupling. Align the flat in the coupling with the flat on the input shaft.
    Steering gear-to-frame bolts. Torque the bolts to 100 ft. lbs. (135 Nm)
    Flexible coupling pinch bolt. Torque the pinch bolt to 22 ft. lbs. (30 Nm)



    Pitman arm onto the Pitman shaft, lining up the marks made at removal. Torque the nut to 215 ft. lbs. (285 Nm).
    Adapter and shield
    Fluid lines and refill the reservoir with the proper power steering fluid

  2. Properly bleed the system and verify no leaks.
  3. Road test the vehicle for proper steering system operation.

These vehicles use a conventional power steering gear with a recirculating ball system. All tubes, hoses and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Be sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Inspect the hoses with the wheels in the straight-ahead position. Then, turn the wheels fully to the left and right while observing the movement of the hoses. Correct any hose contact with other parts of the vehicle that could cause chafing or wear. Power steering hoses and pipes should not be twisted, kinked or tightly bent. The hoses should have sufficient natural curvature in the routing to absorb movement and hose shortening during vehicle operation.

  1. Before servicing the vehicle, refer to the Precautions section.

    Click image to see an enlarged view

    Fig. 3 long bolts attach the power steering gear to the driver-s side frame rail

  2. Set the front wheels in the straight-ahead position.
  3. Place a drain pan under the steering gear and disconnect the fluid lines. Cap the openings to protect the system from contamination.
  4. Remove or disconnect the following:

    Negative battery cable
    Adapter and shield from the gear and flexible coupling
    Flexible coupling clamp and steering box input shaft, matchmark for reassemble
    Flexible coupling pinch bolt
    Pitman arm to the Pitman shaft, matchmark for reassemble
    Pitman shaft nut and lockwasher
    Pitman arm from the shaft using the proper puller
    Steering gear to frame bolts
    Gear assembly


To install:

  1. Install or connect the following:
    NOTE
    Check that the relationship of the flexible coupling to the flange is 1 / 4 - 3 / 4 in. (6-19mm) of flat.



    Steering gear in position, guiding the input shaft into the flexible coupling. Align the flat in the coupling with the flat on the input shaft.
    Steering gear-to-frame bolts. Torque the bolts to 100 ft. lbs. (135 Nm).
    Flexible coupling pinch bolt. Torque the pinch bolt to 22 ft. lbs. (30 Nm).



    Pitman arm onto the Pitman shaft, lining up the marks made at removal. Torque the nut to 215 ft. lbs. (285 Nm).
    Adapter and shield
    Fluid lines and refill the reservoir with the proper power steering fluid

  2. Properly bleed the system and verify no leaks.
  3. Road test the vehicle for proper steering system operation.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Raise the vehicle.
  3. Remove the shield.
  4. Place a drain pan below the steering gear.
  5. Remove or disconnect the following:

    Hoses from the steering gear
    Intermediate shaft from the steering gear
    Pitman arm from the relay rod
    Steering gear frame bolts and the steering gear


To install:

Click image to see an enlarged view

Fig. Recirculating ball gear

  1. Place the steering gear in position.
  2. Install or connect the following:

    Steering gear to the frame bolts. Tighten the bolts to 100 ft. lbs. (135 Nm).
    Pitman arm
    Intermediate shaft

  3. Remove the plugs and the caps from the steering gear and the hoses. Connect the hoses to the steering gear. Tighten the hose connection to 20 ft. lbs. (28 Nm).
  4. Install the shield.
  5. Fill and bleed the system.
  6. Lower the vehicle.

  1. Raise and support the front end on jack stands.
  2. Remove as much power steering fluid from the reservoir as possible.
  3. Remove the engine under cover.
  4. On diesel models, remove the wheelhouse liner.
  5. Disconnect the hoses from the steering gear. Plug the lines to prevent leakage and contamination.
  6. Disconnect the steering shaft coupling from the gear.
  7. Remove the pitman arm nut, then separate the arm from the relay rod using puller J24319-B or equivalent.
  8. Remove the steering gear bolts and remove the gear from the vehicle.

To install:

  1. Install the gear in the vehicle. Tighten the bolts to 110 ft. lbs. (150 Nm).
  2. Connect the pitman arm to the relay rod.
  3. Connect the power steering hoses. Tighten the fittings to 24 ft. lbs. (32 Nm).
  4. The remaining installation is the reverse of removal. Bleed the power steering system.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-2007 models



    Removal & Installation



    Drag (Center) Link



    C3hd Series Only
    1. Raise the front of the truck and support it on safety stands.
    2. Remove the nuts from the Pitman arm and drag link ball studs.
    3. Press the link off the arm and the tie rod.
    4. Install the link. Tighten the Pitman arm ball stud to 46 ft. lbs. (62 Nm) to seat the tapers. Tighten both ball stud nuts to 40 ft. lbs. (54 Nm).

    Idler Arm



    1. Raise and properly support the vehicle.
    2. Remove the idler arm ball stud nut. Discard the nut.
    3. Using a screw-type ball joint tool, separate the idler arm from the relay rod.

    To install:

    1. Make sure that the threads on the ball stud and in the ball stud nut are clean and smooth. If threads are not clean and smooth, ball stud may turn in the socket when attempting to tighten nut. Check condition of ball stud seal; replace if necessary.
    2. Position the idler arm on the frame and install the mounting bolts. On C/K series, tighten the frame-to-bracket bolts to 71 ft. lbs. (96 Nm).
    3. Install the idler arm ball stud in the relay rod, making certain the seal is positioned properly. On C/K series, tighten the new ball stud nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    4. Lower the vehicle.


    NOTE
    Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints.

    1. Raise the vehicle.
    2. Remove the engine protection shield, if equipped.
    3. Remove the idler arm ball stud nut. Do not reuse the idler arm ball stud nut.
    4. Remove the idler arm from the relay rod using tool J24319B or equivalent.
    5. Remove the idler arm frame bolts and the nuts.
    6. Remove the idler arm from the vehicle.

    To install:

    1. Position the idler arm on the frame.
    2. Install the frame bolts and the nuts to the idler arm.
    3. Tighten the frame bolts or nuts to 73 ft. lbs. (99 Nm).
    4. Install the relay rod to the idler arm ball stud. Ensure the seal is on the stud.
    5. Use tool J29193 or equivalent in order to seat the tapers.
    6. Tighten tool to 40 ft. lbs. (54 Nm) in order to seat the tapers.
    7. Install the new idler arm ball stud prevailing torque nut to the idler arm ball stud.
    8. Tighten the nut to 46 ft. lbs. (62 Nm).
    9. Install the engine protection shield, if equipped.
    10. Lower the vehicle.
    11. Check the wheel alignment.

    1. Raise and properly support the vehicle.
    2. Remove the idler arm ball stud nut. Discard the nut.
    3. Using a screw-type ball joint tool, separate the idler arm from the relay rod.

    To install:

    1. Make sure that the threads on the ball stud and in the ball stud nut are clean and smooth. If threads are not clean and smooth, ball stud may turn in the socket when attempting to tighten nut. Check condition of ball stud seal; replace if necessary.
    2. Position the idler arm on the frame and install the mounting bolts. On 2005-06 models, tighten the frame-to-bracket bolts to 71 ft. lbs. (96 Nm). On 2007 models, tighten to 78 ft. lbs. (105 Nm).
    3. Install the idler arm ball stud in the relay rod, making certain the seal is positioned properly. Tighten the new ball stud nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    4. Lower the vehicle.

    Pitman Arm



    1. Raise and properly support the vehicle.
    2. Remove nut from Pitman arm ball stud.

      Click image to see an enlarged view

      Fig. Removing the Pitman arm

    3. On C/K series, break loose the Pitman ball stud from the relay rod using a screw-type ball stud tool. Pull on the linkage to remove the stud.

      Click image to see an enlarged view

      Fig. Typical steering linkage components-C-Series

    4. If necessary, unbolt the steering gear from the frame.
    5. Remove the Pitman arm nut from the Pitman shaft or the clamp bolt from the Pitman arm, and mark the relation of the arm position to the shaft.
    6. Remove Pitman arm, using a large puller.

    To install:

    1. Install the Pitman arm on the Pitman shaft, lining up the marks made upon removal.
    2. Make sure that the threads on the ball studs and in the ball stud nuts are clean and smooth. If threads are not clean and smooth, ball studs may turn in their sockets when attempting to tighten the nut. Check the condition of the ball stud seals; replace if necessary.
    3. Install the Pitman shaft nut or Pitman arm clamp bolt and tighten to 184 ft. lbs. (249 Nm).
    4. If removed, bolt the steering gear to the frame.
    5. Position the ball stud onto the Pitman arm or relay rod.
    6. Tighten the Pitman arm-to-relay rod nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    7. Lubricate ball studs.
    8. Lower the vehicle to the floor.

    1. Raise the vehicle.
    2. Suitably support the vehicle with jack stands.
      NOTE
      Use the proper tool in order to separate the ball joints.

    3. Remove the relay rod nut from the Pitman arm ball stud. Do NOT reuse the relay rod nut.
    4. Use tool J24319-01 in order to remove the relay rod (10) from the Pitman arm ball stud.
    5. Remove the Pitman arm nut (8) and the Pitman arm washer.
    6. Mark the Pitman arm (1) and the Pitman shaft in order to ensure the proper alignment at assembly.
      WARNING
      Do not hammer on the pitman arm, pitman arm shaft or puller. Damage to the pitman arm or steering gear may result.

    7. Use tool J6632-01 in order to remove the Pitman arm.
    8. Inspect the ball stud threads for damage.
    9. Inspect the ball stud seals for excessive wear.
    10. Clean the threads on the ball stud.

    To install:

    1. Install the Pitman arm on the Pitman shaft.
    2. Align the marks made at removal.
    3. Install the Pitman arm washer and the Pitman arm nut.
    4. Tighten the Pitman arm nut to 184 ft. lbs. (250 Nm).
    5. Install the relay rod to the Pitman arm ball stud. Make sure the seal is on the Pitman arm ball stud.
    6. Use tool J29193 in order to seat the tapers.
    7. Tighten tool J29193 to 46 ft. lbs. (62 Nm).
    8. Remove tool J29193 .
    9. Install the new prevailing torque nut.
    10. Tighten the new prevailing torque nut to 46 ft. lbs. (62 Nm).
    11. Lower the vehicle.

    1. Raise the vehicle.
    2. Suitably support the vehicle with jack stands. Important: Use the proper tool in order to separate the ball joints.
    3. Remove the drag link from the Pitman arm ball stud.
    4. Remove the Pitman arm nut from the steering gear shaft.
    5. Mark the Pitman arm and the Pitman shaft in order to ensure the proper alignment at assembly.
    6. Use tool J6632-01or tool J29107-A in order to remove the Pitman arm.
    7. Inspect the following:

      The ball stud threads for damage.
      The ball stud seals for excessive wear.

    8. Clean the threads on the ball stud.

    To install:


    WARNING
    If a clamp-type pitman arm is used, spread the pitman arm just enough with a wedge to slip the arm onto the pitman shaft. Do not spread the pitman arm more than required to slip over the pitman shaft with hand pressure. Do not hammer. Damage to the steering gear may result.

    1. Install the Pitman arm on the Pitman arm shaft.
    2. Line up the marks made at removal.
    3. Install the Pitman arm washer and the nut.
    4. Tighten the Pitman arm nut to 184 ft. lbs. (250 Nm).
    5. Install the drag link to the Pitman arm ball stud.
    6. Make sure the ball stud seal is on the ball stud.
    7. Tighten tool J29193 to 48 ft. lbs. (62 Nm) in order to seat the tapers.
    8. Remove tool J29193.
    9. Install the Pitman arm nut to the Pitman arm ball stud.
    10. Tighten the Pitman arm nut to 35 ft. lbs. (47 Nm).
    11. Lower the vehicle.

    1. Raise and suitable support the vehicle.
    2. Remove the power steering gear.
    3. Install the power steering gear into a vise.
    4. Remove the pitman arm nut and washer.
    5. Remove the pitman arm from the pitman shaft using J6632-01, J29107A, or equivalent.

    To install:

    1. Install the pitman arm to the power steering gear.
    2. Install a new pitman arm washer and nut.
    3. Tighten the nut to 184 ft. lbs. (250 Nm).
    4. Remove the power steering gear from the vise.
    5. Install the power steering gear.
    6. Lower the vehicle.
    7. Check the wheel alignment.

    1. Raise and properly support the vehicle.
    2. Remove nut from Pitman arm ball stud.

      Click image to see an enlarged view

      Fig. Removing the Pitman arm

    3. Break loose the Pitman ball stud from the relay rod using a screw-type ball stud tool. Pull on the linkage to remove the stud.

      Click image to see an enlarged view

      Fig. Typical steering linkage components

    4. If necessary, unbolt the steering gear from the frame.
    5. Remove the Pitman arm nut from the Pitman shaft or the clamp bolt from the Pitman arm, and mark the relation of the arm position to the shaft.
    6. Remove Pitman arm, using a large puller.

    To install:

    1. Install the Pitman arm on the Pitman shaft, lining up the marks made upon removal.
    2. Make sure that the threads on the ball studs and in the ball stud nuts are clean and smooth. If threads are not clean and smooth, ball studs may turn in their sockets when attempting to tighten the nut. Check the condition of the ball stud seals; replace if necessary.
    3. Install the Pitman shaft nut or Pitman arm clamp bolt and tighten to 184 ft. lbs. (249 Nm).
    4. If removed, bolt the steering gear to the frame.
    5. Position the ball stud onto the Pitman arm or relay rod.
    6. Tighten the Pitman arm-to-relay rod nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    7. Lubricate ball studs.
    8. Lower the vehicle to the floor.

    C3hd Series
    1. Raise and properly support the vehicle.
    2. Disconnect the drag link from the Pitman arm ball stud.
    3. Matchmark the Pitman arm to the Pitman shaft, remove the nut from the steering gear shaft and discard it.
    4. Remove the Pitman arm with the proper tool (ball joint puller).
    5. Install the arm so the marks line up with those on the shaft. Tighten the nut to 184 ft. lbs. (250 Nm). Tighten the ball stud nut to 48 ft. lbs. (62 Nm).

    Relay Rod (Center Link)



    1. Raise and properly support the vehicle.
    2. Disconnect the steering shock absorber from the relay rod.
    3. Remove the nut and disconnect the inner tie rod ball joint from the relay rod using a screw-type ball joint tool. Discard the nut.
    4. Remove the nuts from the Pitman and idler arm ball studs at the relay rod. Discard the nuts.
    5. Using a screw-type ball joint tool, disconnect the relay rod from the Pitman and idler arm.
    6. Remove the relay rod from the vehicle.

    To install:

    Installation is the reverse of removal but please note the following important steps.

    1. Make sure that threads on the ball studs and in the ball stud nuts are clean and smooth. If the threads are not clean and smooth, ball studs may turn in sockets when attempting to tighten nut. Check condition of ball stud seals; replace if necessary.
    2. Connect the relay rod to the idler arm and Pitman arm ball studs, making certain the seals are in place. Tighten the new ball stud nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    3. Install the tie rod to the center link. Tighten the new nut to 40 ft. lbs. (54 Nm).
    4. Install the shock absorber. Tighten the frame end nut to 30 ft. lbs. (40 Nm); the relay rod end nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!

    1. Raise the vehicle.
    2. Suitably support the vehicle with jack stands.
    3. Remove the steering shock absorber from the relay rod, if equipped.
      NOTE
      Use the proper tool in order to separate all the tie rod and the ball joints.

    4. Remove the inner tie rod ball joint from the relay rod.
    5. Remove the idler arm ball stud nut. Do NOT reuse.
    6. Remove the Pitman arm nut. Do NOT reuse.
    7. Remove the relay rod from the idler arm ball stud using tool J24319-01 .
    8. Remove the relay rod from the Pitman arm ball stud using tool J24319-01 .
    9. Inspect the threads on the tie rod for damage.
    10. Inspect the ball stud threads for damage.
    11. Inspect the ball stud seals for excessive wear.
    12. Clean the threads on the ball stud.

    To install:

    1. Install the relay rod to the idler arm ball stud.
    2. Install the relay rod to the Pitman arm ball stud; make sure the seal is on the stud.
    3. Install tool J24319-01 or tool J29194 to the ball stud.
    4. Tighten the steering linkage installer to 46 ft. lbs. (62 Nm) in order to seat the tapers.
    5. Remove tool J24319-01 or tool J29194.
    6. Install the new idler arm prevailing torque nut.
    7. Tighten the nuts to 46 ft. lbs. (62 Nm).
    8. Install the new Pitman arm prevailing torque nut.
    9. Install the tie rod inner ball joints to the relay rod.
    10. Install the steering shock absorber to the relay rod, if equipped.

    1. Raise and properly support the vehicle.
    2. Disconnect the steering shock absorber from the relay rod.
    3. Remove the nut and disconnect the inner tie rod ball joint from the relay rod using a screw-type ball joint tool. Discard the nut.
    4. Remove the nuts from the Pitman and idler arm ball studs at the relay rod. Discard the nuts.
    5. Using a screw-type ball joint tool, disconnect the relay rod from the Pitman and idler arm.
    6. Remove the relay rod from the vehicle.

    To install:

    Installation is the reverse of removal but please note the following important steps.

    1. Make sure that threads on the ball studs and in the ball stud nuts are clean and smooth. If the threads are not clean and smooth, ball studs may turn in sockets when attempting to tighten nut. Check condition of ball stud seals; replace if necessary.
    2. Connect the relay rod to the idler arm and Pitman arm ball studs, making certain the seals are in place. Tighten the new ball stud nut to 46 ft. lbs. (62 Nm). Always advance the nut to align the cotter pin hole. NEVER back it off!
    3. Install the tie rod to the center link.
    4. Install the shock absorber.

    Steering Damper



    1. Raise and properly support the vehicle.
    2. Remove the frame end nut and bolt.
    3. Remove the cotter pin and nut from the relay rod end. It may be necessary to separate the shock from the relay rod with a screw-type ball joint tool.

      Click image to see an enlarged view

      Fig. Steering shock absorber-C-Series



      Click image to see an enlarged view

      Fig. Steering shock absorber-K-Series

    4. Install the shock and tighten the frame end nut and bolt to 33 ft. lbs. (45 Nm); the relay rod end nut to 46 ft. lbs. (62 Nm).Always advance the nut to align the cotter pin hole. NEVER back it off! A maximum torque of 59 ft. lbs. (80 Nm) is permissible to align the hole.

    Steering Linkage Shock Absorber (Damper)



    1. Raise and properly support the vehicle.
    2. Remove the frame end nut and bolt.
    3. Remove the cotter pin and nut from the relay rod end. It may be necessary to separate the shock from the relay rod with a screw-type ball joint tool.

      Click image to see an enlarged view

      Fig. Steering shock absorber-2005-06 models



      Click image to see an enlarged view

      Fig. Steering shock absorber-2007 models

    4. Install the shock and tighten the frame end nut and bolt to 33 ft. lbs. (45 Nm); the relay rod end nut to 46 ft. lbs. (62 Nm).Always advance the nut to align the cotter pin hole. NEVER back it off! A maximum torque of 59 ft. lbs. (80 Nm) is permissible to align the hole.

    Tie Rod Ends



    1. Raise and support the front end on jack stands.
    2. Remove the nut from the knuckle end ball stud. Discard the nut.

      Click image to see an enlarged view

      Fig. Tie rod clamp and adjuster tube positioning-C3HD-Series



      Click image to see an enlarged view

      Fig. Tie rod clamp and adjuster tube positioning-C/K-Series

    3. Using a screw-type ball joint tool, separate the tie rod ball stud from the knuckle.
    4. On all except C3HD models, remove the nut from the inner tie rod ball stud.
    5. Using a screw-type ball joint tool, separate the tie rod ball stud from the relay rod.
    6. Clean the threaded parts of the tie rod ends thoroughly and count the exact number of threads exposed on each tie rod end. Measure the overall length of the tie rod assembly.
    7. Loosen the clamp nuts, spread the clamps and unscrew each tie rod end.

    To install:

    1. Coat the threaded parts of the new tie rod ends with chassis grease. Screw the tie rod ends into the sleeve until the exact number of threads is exposed on each tie rod end. Check the overall length of the new assembly. Adjust as necessary. Don't tighten the clamp nuts yet.
    2. On all except C3HD models, position the tie rod assembly in the relay rod and install a new nut on the ball stud. Tighten the nut to 40 ft. lbs. (54 Nm).
    3. Position the other tie rod end in the knuckle. Install the new nut and tighten it to 46 ft. lbs. (62 Nm) on (except C3HD). On C3HD models, tighten the nut to 65 ft. lbs. (88 Nm).
    4. Before tightening the clamp nuts, position the clamp as shown in the accompanying illustrations.
    5. Tighten the clamp nuts 18 ft. lbs. (25 Nm) (except C3HD). On C3HD models, tighten the clamp nuts to 65 ft. lbs. (88 Nm).

    1. Raise and support the front end on jack stands.
    2. Remove the nut from the knuckle end ball stud. Discard the nut.

      Click image to see an enlarged view

      Fig. Tie rod clamp and adjuster tube positioning-2005-06 models

    3. Using a screw-type ball joint tool, separate the tie rod ball stud from the knuckle.
    4. Remove the nut from the inner tie rod ball stud.
    5. Using a screw-type ball joint tool, separate the tie rod ball stud from the relay rod.
    6. Clean the threaded parts of the tie rod ends thoroughly and count the exact number of threads exposed on each tie rod end. Measure the overall length of the tie rod assembly.
    7. Loosen the clamp nuts, spread the clamps and unscrew each tie rod end.

    To install:

    1. Coat the threaded parts of the new tie rod ends with chassis grease. Screw the tie rod ends into the sleeve until the exact number of threads is exposed on each tie rod end. Check the overall length of the new assembly. Adjust as necessary. Don't tighten the clamp nuts yet.
    2. Position the tie rod assembly in the relay rod and install a new nut on the ball stud. Tighten the nut to 40 ft. lbs. (54 Nm).
    3. Position the other tie rod end in the knuckle. Install the new nut and tighten it to 46 ft. lbs. (62 Nm).
    4. Before tightening the clamp nuts, position the clamp as shown in the accompanying illustrations.
    5. Tighten the clamp nuts 18 ft. lbs. (25 Nm).


    STEERING WHEEL REMOVAL;---
    1. Disconnect the battery ground cable.
    2. On models equipped with a drivers side air bag, perform the following procedure:
      1. Disable the Supplemental Restraint System (if equipped).
      2. On models equipped with a air bag, turn the steering wheel 90° to access the rear shroud holes to the inflator module. Insert a screwdriver in the holes and push the leaf spring to release the pin. Turn the steering wheel 180° to access the remaining shroud holes and using the screwdriver, release the remaining pins.
      3. Tilt the inflator module rearward from the top to access the wiring. Tag and unplug the lead wire from the clip on the module, the lead wire from the clip on the steering wheel and the Connector Position Assurance (CPA) and retainer from the module.

    3. If not equipped with a drivers side air bag, remove the horn pad or button cap and disconnect the horn wires.

      Click image to see an enlarged view

      Fig. Remove the horn button cap



      Click image to see an enlarged view

      Fig. Disengage the horn wiring



      Click image to see an enlarged view

      Fig. If equipped, remove the snapring from the steering shaft

    4. Mark the steering wheel-to-steering shaft relationship.
    5. If equipped, remove the snapring from the steering shaft.
    6. Remove the nut from the steering shaft.
      WARNING
      Don't hammer on the steering shaft!

    7. Remove the steering wheel with a puller.

    To install:

    1. Install the wheel. The turn signal control assembly must be in the Neutral position to prevent damaging the canceling cam and control assembly. Tighten the nut to 30 ft. lbs. (40 Nm).
    2. Install the horn pad and horn contact (if equipped).
    3. If equipped with a drivers side air bag, install the inflator module as follows:
      1. Attach the lead wire to the clip on the module, the lead wire to the clip on the steering wheel and the Connector Position Assurance (CPA) and retainer to the module.
      2. Install the inflator module by pressing it firmly into the steering wheel so that all four notched pins in the leaf spring are fully engaged. Be very careful that you do not pinch any wires.

    4. Connect the battery ground cable and enable the SIR system (if equipped).

      Click image to see an enlarged view

      Fig. Remove the nut and washer from the steering shaft



      Click image to see an enlarged view

      Fig. Use a puller to separate the steering wheel



      Click image to see an enlarged view

      Fig. Remove the steering wheel


    1. Disable the Supplemental Inflatable Restraint (SIR) system (if equipped), as outlined in the Chassis Electrical Section.
    2. Remove the inflator module.
    3. Remove the horn pad assembly (if not equipped with an SIR).
    4. Remove the horn switch.
    5. Make an alignment mark in order to note the relationship of the steering wheel to the steering shaft.
    6. Remove the steering wheel nut.
    7. Use tool J1859A or equivalent in order to remove the steering wheel.

      Click image to see an enlarged view

      Fig. Use tool J1859A or equivalent in order to remove the steering wheel.


    To install:

    1. Align the marks made during the removal procedure on the steering shaft and the steering wheel.
    2. Install the steering wheel nut to the steering shaft.
    3. Tighten the nut to 30 ft. lbs. (40 Nm).
    4. Install the horn switch.
    5. Install the horn pad assembly, if not equipped with an SIR.
    6. Install the inflator module.
    7. Enable the SIR system, if equipped.


    CAUTION
    When performing service around the SIR system components or wiring, the SIR system MUST be disabled. Failure to do so could result in possible air bag deployment, personal injury or unneeded SIR system repairs.

    1. Disconnect the battery ground cable.
    2. Remove the air bag:
      1. Disable the Supplemental Restraint System.
      2. T urn the steering wheel 90° to access the rear shroud holes to the inflator module. Insert a screwdriver in the holes and push the leaf spring to release the pin. Turn the steering wheel 180° to access the remaining shroud holes and using the screwdriver, release the remaining pins.
      3. Tilt the inflator module rearward from the top to access the wiring. Tag and unplug the lead wire from the clip on the module, the lead wire from the clip on the steering wheel and the Connector Position Assurance (CPA) and retainer from the module.

    3. Mark the steering wheel-to-steering shaft relationship.
    4. If equipped, remove the snapring from the steering shaft.
    5. Remove the nut from the steering shaft.
      WARNING
      Don't hammer on the steering shaft!

    6. Remove the steering wheel with a puller.

      Click image to see an enlarged view

      Fig. Exploded view of the steering wheel assembly


    To install:

    1. Install the wheel. The turn signal control assembly must be in the Neutral position to prevent damaging the canceling cam and control assembly. Tighten the nut to 30 ft. lbs. (40 Nm).
    2. Install the inflator module as follows:
      1. Attach the lead wire to the clip on the module, the lead wire to the clip on the steering wheel and the Connector Position Assurance (CPA) and retainer to the module.
      2. Install the inflator module by pressing it firmly into the steering wheel so that all four notched pins in the leaf spring are fully engaged. Be very careful that you do not pinch any wires.

    3. Connect the battery ground cable and enable the SIR system.

      Click image to see an enlarged view

      Fig. Remove the nut and washer from the steering shaft



      Click image to see an enlarged view

      Fig. Use a puller to separate the steering wheel



      Click image to see an enlarged view

      Fig. Remove the steering wheel




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