TECHNICAL INSTRUCTIONS

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1 TECHNICAL INSTRUCTIONS REPLACEMENT THE STEERING INTERMEDIATE SHAFT ASSEMBLY FJ CRUISER For LHD 1 OPERATION FLOWCHART IDENTIFICATION OF AFFECTED VEHICLES PREPARATION GENERAL DESCRIPTION PRECAUTIONS FOR ALL OPERATIONS COMPONENTS REMOVE THE STEERING INTERMEDIATE SHAFT ASSEMBLY INSTALL THE STEERING INTERMEDIATE SHAFT ASSEMBLY LOOSEN THE STEERING SLIDING YOKE (FOR A CASE OF FIRM ENGAGEMENT)

2 <<SAFETY PRECAUTIONS>> A. Be sure to observe the following precautions to prevent accidents and injuries. Park the vehicle and chock the wheels. If it is necessary to start the engine, perform the operation in a well ventilated area. Before removing and reinstalling heavy parts such as the engine, transmission and differential using lifting equipment, check that there are no problems with the equipment. When working in a group of 2 or more, each person must work to ensure the safety of all team members. To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts. When lifting the vehicle using a jack, support it in the specified location using a rigid rack. When lifting the vehicle using a lift, lock the lift for safety. B. Also perform the following operation with care. Use of auto lift Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as Raising the lift! and Lowering the lift! ) to alert other workers. When raising or lowering the lift to adjust the vehicle position, etc., pay attention to the positions of your arms, legs, and other body parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner Use brake cleaner for appropriate purposes in accordance with instructions in the manual. Do not use brake cleaner to remove dirt or stains from work clothes, etc. It can catch on fire and cause serious burns. Precautions Do not use brake cleaner near flame or fire. Do not use large amounts of brake cleaner in a room where a fire is burning. Do not keep brake cleaner in a place subject to high temperatures exceeding 40 C, such as a place subject to direct sunlight or near fire. Do not put brake cleaner in fire. Edges When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers

3 1 OPERATION FLOWCHART Verify Vehicle Eligibility Check the VIN range. Not Involved No further action required. Replace the steering intermediate shaft assembly. Confirm and realign the steering wheel center position if needed. Campaign completed, return the vehicle to the customer

4 2 IDENTIFICATION OF AFFECTED VEHICLES AFFECTED VEHICLE IDENTIFICATION NUMBER Model Model Code Model Year VIN Range WMI VDS VIS Production Period 2013 BU11F# #K #K August 1, 2013 FJ GSJ15 through JTE BU4BF# #K #K through CRUISER 2014 ZU4BF# #K #K August 23, 2013 NOTE: # indicates that various characters may occupy that position. As for the total number of affected vehicles shipped to your country, please refer to the attached VIN-list. 1. CHECK THE VEHICLE IDENTIFICATION NUMBER (a) Confirm that the VIN is within the range shown in the table above. HINT: The Vehicle Identification Number (VIN) is stamped on location A and B shown in the illustration

5 3 PREPARATION PARTS Part Number Part Description Quantity Others Steering Intermediate Shaft Assembly 1 For LHD Clip 2 For FRONT FENDER SPLASH SHIELD TOOLS&EQUIPMENT Part Number Name Quantity Others - Standard Hand Tools Torque Wrench Clip Remover 1 - MATERIALS & SUPPLIES Name Quantity Others Washer 1 Part Number Protective Tape - - Marking Pen 1 - Work Gloves 1 - Shop Cloth

6 4 GENERAL DESCRIPTION Replace the steering intermediate shaft assembly with a new one

7 5 PRECAUTIONS FOR ALL OPERATIONS 1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK (a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working. (b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way. 2. WEAR PROTECTIVE EYEWEAR (a) Wear protective eyewear when working under vehicle or where there is any risk of flying parts or debris. 3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER (a) Do not spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. Do not use it near cigarettes or stoves as this can cause serious burns and injuries

8 4. AVOID BURNS (a) If the engine is hot, wear protective gloves to prevent burns. 5. PROTECT THE VEHICLE (a) A fender cover, a grill cover, seat covers tape etc. must be used to protect the vehicle from dirt or scratches. The protective measures listed above may not be shown in some illustrations to allow easy identification simple and easy to read. 6. HANDLING OF REMOVED PARTS (a) Destroy or mark and then store removed parts in a separate container so as to not be assembled again in error. (b) Check the removed parts when performing the completion inspection. The parts shown in the illustration to the left are examples only and differ from the actual replacement parts. 7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT (a) Do not break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work

8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 9.

9 8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP (a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left inside the engine compartment. 9. INSPECT FOR STEERING WHEEL STRAIGHTFORWARD POSITION (a) The shaft connection will be engaged in the specified position and any phase shifting of the serration will not occur. However, slight phase shifting caused by the individual difference of an intermediate shaft may occur. 10. BE CAREFUL OF BURR AROUND THE STEERING COLUMN (a) There are burrs on the brake pedal support assembly beside the steering column. Take safety measures such as wearing protective gloves or applying a protective tape to avoid injury

10 6 COMPONENTS

11 7 REMOVE THE STEERING INTERMEDIATE SHAFT ASSEMBLY 1. RECORD POSITIONING OF STEERING COLUMN AND SEAT (a) Note and record the tilt position of the steering column. (b) Note and record the driver side seat. 2. INSPECT FOR STEERING WHEEL STRAIGHTFORWARD POSITION 3. MAKE SPACE FOR WORK (a) Tilt up the steering column to its upper limit. (b) Slide back the driver seat to the rearmost position. 4. HOLD THE STEERING WHEEL IN POSITION (a) Pass the seat belt through the area shown in the illustration to hold the steering wheel in order to prevent the airbag spiral cable from being broken. Do not damage the steering wheel during this process. (b) Put a shop cloth between the seat belt and the steering wheel for prevention of its damage. 5. DISENGAGE THE FRONT FENDER SPLASH SHIELD REAR LH (a) Remove the 2 upper clips using a clip remover and flip the front fender splash shield rear LH. (b) Break the removed 2 clips and store it in a replacement parts box etc

12 6. WEAR GLOVES (a) Always be sure to wear gloves to prevent injuring your hands. 7. REMOVE THE STEERING SLIDING YOKE (a) Put match marks on the steering sliding yoke and the No. 2 steering intermediate shaft sub-assembly for facilitation of reassembly. HINT: The bolts will be reused. The serrations will be engaged in the specified position and any phase shifting will not occur. But the match marks can facilitate alignment of the serrations in reassembly. (b) Remove the 2 bolts. Slide the steering sliding yoke in the direction indicated in the illustration to separate it from the No. 2 steering intermediate shaft sub-assembly. If the engagement is sticking firmly, loosen it with the method shown in 9. LOOSEN THE STEERING SLIDING YOKE. If you are having difficulty removing the sliding yoke from their splines, do not hit them with a hammer or any other tool. Doing so may damage the shock absorbing mechanism or the joints of the steering system. Do not apply lubricant. If lubricant adheres to the threads, the bolt may bleak while being tightened or may loosen due to the lubricant being present

13 (c) Remove the steering sliding yoke from the steering intermediate shaft assembly. HINT: The shaft will be replaced with new one. It is unnecessary to put match marks. The serrations will be engaged in the specified position and any phase shifting will not occur. If the engagement is sticking firmly, loosen it with the method shown in 9. LOOSEN THE STEERING SLIDING YOKE. Do not hit and apply a shock to the steering gear or the main shaft. Do not apply lubricant. (d) Clean removed bolts and adhered grease to the joint surface of the steering sliding yoke. HINT: Clean the adhered grease so as not to allow the cabin to get dirt. It is unnecessary to clean screw part of the steering sliding yoke. (Even if grease is adhering to the screw part, tighten bolts with specified torque.) 8. REMOVE THE STEERING COLUMN HOLE COVER (a) Disengage the 4 clips and remove the steering column hole cover. 9. REMOVE THE STEERING INTERMEDIATE SHAFT ASSEMBLY (a) Pull out the seat belt and keep it slack. (b) Move the driver seat to the frontmost position. Slide the driver seat because it may be impossible to turn the steering wheel held by the seat belt. (c) Turn slowly the steering wheel clockwise approximately 90 degrees to the position where the bolt of the steering intermediate shaft assembly can be removed. Use a shop cloth to protect the steering wheel and turn it slowly so as not to damage it

14 (d) For insertion check of the intermediate shaft assembly, put a mark on the steering main shaft at the height of the upper surface of the steering shaft thrust stopper. (e) Make marks on the steering intermediate shaft assembly to be replaced in order to prevent it from being reinstalled. (f) Remove the bolt and slide the steering shaft thrust stopper upward. HINT: The bolt will be reused. (g) Separate the steering intermediate shaft assembly and the steering shaft thrust stopper from the steering column. If the engagement is sticking firmly, loosen it with the method shown in 9. LOOSEN THE STEERING SLIDING YOKE. Do not hit and apply a shock to the steering gear or the main shaft. Do not apply lubricant. (h) Pull up the steering intermediate shaft assembly to remove it from the vehicle body. Take care not to damage the dust boot. Grease is adhering to the steering intermediate shaft assembly. Take care not to allow the cabin to get dirt. (i) Removed steering intermediate shaft assembly and store it in a replacement parts box etc

15 8 INSTALL THE STEERING INTERMEDIATE SHAFT ASSEMBLY 1. WEAR GLOVES (a) Always be sure to wear gloves to prevent injuring your hands. 2. INSTALL THE STEERING INTERMEDIATE SHAFT ASSEMBLY (a) Pass the new steering intermediate shaft assembly through the dust boot on the vehicle body. Take care not to damage the dust boot. HINT: The grease adhered to the removed steering intermediate shaft assembly is intended to prevent rubbing noise of the dust boot. The grease adhered while passing through the dust boot so that it is unnecessary to apply grease to the new steering intermediate shaft assembly. (b) Attach the steering shaft thrust stopper over the steering main shaft assembly. (c) Connect the steering intermediate shaft assembly to the steering main shaft assembly. HINT: Connect the steering intermediate shaft assembly to the steering main shaft assembly while adjusting their positions so that the recessed area of the steering main shaft aligns with the bolt hole of the steering intermediate shaft. The serrations will be engaged in the specified position and any phase shifting will not occur

16 (d) Insert fully the steering intermediate shaft assembly. Temporarily install the bolt via the steering shaft thrust stopper. (e) Insert a flathead screw driver wound with protective tape into the gap between the steering shaft thrust stopper and the steering main shaft assembly as shown in the illustration and tighten the bolt. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) If the bolt is tightened without the inserted flathead screw driver, the steering shaft thrust stopper turns in the tightening direction resulting in interference with the steering main shaft assembly. (f) Remove the flathead screw driver. (g) Check that there is no interference between the steering shaft thrust stopper and the steering main shaft assembly

17 (h) Check that the mark on the steering main shaft is aligned with the upper surface of the steering shaft thrust stopper. (i) Make a mark on the bolt head in order to confirm that the bolt has been tightened properly. (j) Turn slowly the steering wheel to the straightforward position. Use a shop cloth to protect the steering wheel and turn it slowly so as not to damage it. (k) Move the driver seat to the rearmost position. 3. INSTALL THE STEERING SLIDING YOKE (a) Insert the steering sliding yoke over the steering intermediate shaft assembly. HINT: Insert the steering sliding yoke over the steering intermediate shaft assembly while adjusting their positions so that the flat of the steering intermediate shaft aligns with the bolt hole of the steering sliding yoke. The serrations will be engaged in the specified position and any phase shifting will not occur. In case of adhesion of grease clean the bolt joint surfaces. HINT: Clean the adhered grease so as not to allow the cabin to get dirt. It is unnecessary to clean screw part of the steering sliding yoke. (Even if grease is adhering to the screw part, tighten bolts with specified torque.)

18 (b) Temporarily fix steering sliding yoke with the bolt. (c) Align the match marks and connect the steering sliding yoke to the No. 2 steering intermediate shaft sub-assembly. HINT: The serrations will be engaged in the specified position and any phase shifting will not occur. (d) Insert the steering sliding yoke fully. Temporarily install the bolt. (e) Tighten the 2 bolts. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) (f) Make a mark on the 2 bolts head in order to confirm that the bolt has been tightened properly

19 IMPORTANT 4. INTERMEDIATE INSPECTION If only the edge of the shaft is engaged as shown in the NG illustration below, the bolt can be tightened but the shaft may come off. (a) Check that the removed steering intermediate shaft assembly has been marked as NG. (b) Check that the mark on the steering main shaft assembly is aligned with the upper surface of the steering shaft thrust stopper in order to make sure that the steering intermediate shaft assembly is fully inserted. (c) Make a mark to confirm that the inspection has been performed. (d) Make sure that the both ends of the steering sliding yoke are fully inserted over the respective shafts. (e) Make a mark to confirm that the inspection has been performed

20 5. ENGAGE THE FRONT FENDER SPLASH SHIELD REAR LH (a) Engage the front fender splash shield rear LH with the 2 new clips. 6. INSTALL THE STEERING COLUMN HOLE COVER (a) Install the steering column hole cover with the 4 clips. 7. TURN THE STEERING WHEEL FROM LEFT-TO-RIGHT TO INSPECT FOR PROPER OPERATION AND FEEL (a) Release the seat belt. (b) Check for rough movement or abnormal noise. 8. INSPECT FOR STEERING WHEEL STRAIGHTFORWARD POSITION The shaft connection will be engaged in the specified position and any phase shifting of the serration will not occur. However, slight phase shifting caused by the individual difference of an intermediate shaft may occur. (a) If needed, center the steering wheel by adjusting the tie rod length. 9. TEST DRIVE 10. RETURN THE POSITIONS OF THE STEERING COLUMN AND THE DRIVER SEAT

21 9 LOOSEN THE STEERING SLIDING YOKE (FOR A CASE OF FIRM ENGAGEMENT) 1. LOOSEN THE STEERING SLIDING YOKE (a) Pull out the seat belt and keep it slack. (b) Move the driver seat to the frontmost position. Slide the driver seat because it may be impossible to turn the steering wheel held by the seat belt. (c) Turn slowly the steering wheel counterclockwise approximately 90 degrees to the position where the slit of the steering sliding yoke can be seen. Use a shop cloth to protect the steering wheel and turn it slowly so as not to damage it. [ Method to release sticking engagement with use of a flathead screw driver ] (d) Use a flathead screw driver wound with protective tape to pry the slit to release the sticking engagement of the serrations and separate the steering sliding yoke from the steering intermediate shaft assembly. Do not hit and apply a shock to the steering gear or the main shaft. Do not apply lubricant

22 [ Method to release sticking engagement using a washer ] (In the cases where sticking engagement cannot be released by the procedure (d)) (e) Insert the washer into the slit of the steering sliding yoke and hold the washer by hand. Recommended washer part number: (Outer diameter 30 mm (1.18 in.), inner diameter 14 mm (0.55 in.), and thickness 2.3 mm (0.09 in.)) Also a washer other than the recommended part number can be used, but the thickness must be 2.3 mm (0.09 in.) or larger. If a thinner washer is used, it may be deformed by the tightened bolt and become impossible to be removed. (f) Attach the bolt from the internal thread side of the steering sliding yoke (opposite side to the normal installation). (g) Tighten the bolt by hand. When the bolt contacts with the washer, use a tool to tighten the bolt approximately 90 degrees to release the sticking engagement. (h) Remove the bolt and washer. (i) Remove the steering sliding yoke from the steering intermediate shaft assembly. Do not open the slit to the limit of 3.5 mm (0.14 in.) or larger in order to prevent the steering sliding yoke from being broken

TECHNICAL INSTRUCTIONS

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