ST001R-05 09/08/2005 Steering - Highway Speed Steering 'Flutter'

[CBR_GUY_IA]

NOTE: This bulletin has 5 sub bulletins and goes three replies long

Steering - Highway Speed Steering 'Flutter'
Information
Steering - Highway Speed Steering 'Flutter'
Diagnostic Procedure
Dunlop Tire Flat Spotting Diagnosis/Tire Balance Procedure
Steering Rack Guide Preload Spring Installation Procedure
Increased Mass Steering Wheel Installation Procedure

#1

STEERING
ST001-05
REVISED

July 28, 2005

Title:
STEERING FLUTTER FIELD - FIX PROCEDURE

Models:
'03 - '05 4Runner

TSB REVISION NOTICE:

^ September 8, 2005: The contact information in the "Obtaining Replacement Tires" section of the "Dunlop Tire Flat Spotting Diagnosis" procedure has been updated. Previous versions of this TSB should be discarded.


Introduction

Some customers may experience a steering flutter condition while driving at highway speeds. In most cases, this concern is caused by flat spots that can normally develop in the tires after sitting for long periods of time. To minimize the effects of flat spotting and other minor tire irregularities, a new repair procedure has been developed that includes installing improved components to help reduce steering flutter complaints.

Applicable Vehicles^ 2003 - 2005 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown.








Warranty Information

Applicable Warranty:

This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.







Production Change Information







Parts Information







Required Tools & Material







Required SSTs

#2

Steering - Highway Speed Steering 'Flutter'
Notes





Notes










#3

Notes







The following instructions apply only to black sidewall P265/65R17 110S Dunlop AT20 original equipment tires produced in Japan before the production week 0905. Tires produced on or after production week 0905 do NOT qualify for this program. The last four digits of the tire DOT number represent the production week. This procedures does NOT apply to vehicles equipped with Dunlop AT20 original equipment tires produced in the U.S.A.

After the tires have been warmed up for a minimum 10 minutes at 65 mph (104.6 km/h), the vehicle should be immediately raised on the hoist. The tires may be checked with a dial indicator placed at the center rib of the tread design.







If the tires are flat spotted, there will be a short duration dip in the runout gauge reading equal to the approximate size of the tire's footprint, or approximately 3 - 7 inches (7.6 - 17.8 cm) of the tread circumference. The dip in the reading on the runout gauge will go in and out the same amount; it is not just a short duration but an abrupt change in the reading. Flat spotting will NOT be visible by eye and requires the use of a dial indicator. Flat spotting should NOT be confused with any external abrasion on the tire (such as a panic stop) that causes the tread depth in the tire's footprint area.







If the runout between A and B exceeds 0.020 - 0.040 inches (0.051 - 0.102 cm) over 3 - 7 inches (7.6 - 17.8 cm) of the tread circumference, this may cause a ride complaint depending on the vehicle sensitivity.

If the tires are not flat spotted but the assembly runout is greater than desired, then standard match mounting and balancing procedures should be followed.

Obtaining Replacement Tires:

Tires with 9/32 or greater tread depths that are flat spotted based on the above criteria may be exchanged at no charge through a Dunlop dealer. It is recommended that all four tires be exchanged when flat spotting has occurred. For dealers participating in the Toyota Tire Center Program, please contact Program Headquarters for instructions. For dealers not participating in the Toyota Tire Center Program, your local Dunlop dealer must call the Goodyear/Dunlop Customer Assistance Center at 1-800-321-2136 for authorization to return the tires through the Goodyear/Dunlop warranty system.

Tire Balance Procedure







Mount the tire/wheel assembly to the tire balancer as illustrated. When balancing the tire, ensure that the Road Force function of the balancer is turned ON and the "Haweka" type balancing adapter MUST be used when balancing these tires. (Refer to your balancer owner's manual for further information about Road Force variation measurements on tire and wheel assemblies.) This is necessary to ensure that the wheels and tires are match mounted (heavy portion of tire is matched with light side of wheel or visa-versa).

Remount the tire and wheel assembly to the vehicle. Torque all wheels.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.lbf)

 

[admin]

#4

PRECAUTION:

^ The 4Runner is equipped with SRS, which consists of a driver airbag, front passenger airbag, side airbag, and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection. or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.

^ Wait at least 90 seconds AFTER the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)

^ Do not expose the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor directly to hot air or flames.

NOTE: ^ Malfunction symptoms of the SRS are difficult to confirm, so the DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.

^ Even in cases of a minor collision when the SRS does not deploy, the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, and seat position airbag sensor should be inspected.

^ Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation.

^ Never use SRS parts from another vehicle. When replacing parts, replace them with new ones.

^ Never disassemble and repair the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor in order to reuse them.

^ If the horn button assembly, front passenger airbag assembly, airbag sensor assembly center, airbag front sensor, front seat airbag assembly, side airbag sensor assembly, curtain shield airbag assembly, airbag sensor rear, or seat position airbag sensor has been dropped, or if there are any cracks, dents, or other defects in the case, bracket, or connector, replace it with a new one.

^ Use a volt/ohmmeter with high impedance (10 kOhms/V minimum) for troubleshooting the electrical circuits.

^ Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.

^ After work on the SRS is completed, perform the SRS warning light check.

^ When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be cancelled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio system as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle.

^ If the vehicle is equipped with a mobile communication system, refer to the preceding Precaution.

1. Place the front wheels facing straight ahead with the engine running.

2. Record the radio presets.

3. Turn the key to the OFF position and remove the keys from the ignition.

4. Disconnect the negative (-) battery terminal.

5. Remove the front wheels.

6. Remove the 6 bolts and the engine under cover assembly rear.

7. Remove the 4 bolts and the engine under cover sub-assembly No. 1.

8. Remove the 2 nuts and the front stabilizer link assembly LH.

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








9. Remove the 2 nuts and the front stabilizer link assembly RH.








10. Remove the 2 bolts and the front stabilizer bracket No. 1 LH.

11. Remove the 2 bolts and the front stabilizer bracket No. 1 RH.

12. Remove the 2 front stabilizer bar bushings No. 1.

13. Remove the front stabilizer bar.

14. Separate the tie rod end sub-assembly LH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011









15. Separate the tie rod end sub-assembly RH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011


16. Remove the steering sliding yoke.








A. Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2, and steering intermediate shaft assembly.

B. Remove bolt A and bolt B from the steering sliding yoke.

C. Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2.

D. Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove.

17. Remove steering intermediate shaft No. 2.

A. Mark the matchmarks on the power steering gear assembly and steering intermediate shaft sub-assembly No. 2.

B. Remove bolt C and the intermediate shaft sub-assembly No. 2 from the power steering gear assembly.


18. Disconnect the pressure feed tube assembly.








A. Using the 17 mm Union nut wrench (or equivalent), loosen the flare nut and disconnect the pressure feed tube.








B. Remove the 2 bolts and separate the pressure feed tube assembly from the frame sub-assembly.








19. Disconnect the steering gear outlet return tube.

A. Remove the clip and disconnect the return hose.









B. Using the 17 mm Union nut wrench (or equivalent), remove the outlet return tube.








20. Remove the 2 bolts, 2 nuts, and power steering link assembly.

NOTE: Be sure to only turn the bolt as the nut has a detent.

HINT: After loosening the 2 bolts, raise the bolt from the frame. Slide the power steering gear assembly and the bolt as a unit to the position where the bolt can be pulled out.








21. Carefully secure the power steering gear assembly in a vise (if available, use SST P/N: 09612-00012-01).

22. Remove the rack guide.








A. Using the SST, remove the lock nut as shown in the illustration.

SST P/N: 09922-10010-01








B. Using a hexagon wrench (24 mm), remove the rack guide spring cap.

C. Remove the spring and rack guide.

23. Install the rack guide spring.

A. Install the rack guide and new spring (P/N: 44215-35010).

B. Apply sealant to 2 or 3 threads of the rack guide spring cap.

Sealant: Three Bond 1344, Loctite 242, or equivalent.









C. Using a hexagon wrench (24 mm), temporarily install the spring cap.

24. Adjust the total preload.








A. Using a hexagon wrench (24 mm), tighten the rack guide spring cap.

Torque: 25 N.m (250 kgf.cm, 18 ft.-lbf)

B. Turn the cap an additional 30°counterclockwise.








C. Using the SST, turn the control valve shaft right and left 1 or 2 times.

^ SST P/N: 09616-00010-02


D. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring has no tension.








E. Using the SST, a torque wrench, and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

^ SST 09616-00010-02

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in..lbf)


NOTE: When making the adjustment, be sure to turn the cap in the clockwise direction.

F. Apply sealant to 2 or 3 threads of the lock nut.

Sealant: Three Bond 1344, Loctite 242, or equivalent

G. Temporarily install the lock nut.








H. Using a hexagon wrench (24 mm), holding the rack guide from rotating, and using the SST, torque the nut.

^ SST 09922-10010-01

Torque: 69 N.m (700 kgf.cm, 51 ft.-lbf) for use with SST


I. Recheck the total preload.

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in.-lbf)








25. Install the power steering link assembly into the vehicle with the 2 bolts and 2 nuts. Torque: 100 N.m (1,020 kgf.cm, 74 ft.-lbf)

NOTE: The nut has a detent, so never turn the nut. Be sure to turn the bolt.

NOTE: Insert the bolts and position it with the power steering gear assembly as a unit.

Then install the bolts on the frame.








26. Install the front stabilizer bar.

27. Install the 2 front stabilizer bar bushings No. 1.

NOTE: ^ Install the bushing to the inner side of the bushing stopper on the stabilizer bar.









^ Install the stabilizer bushing No. 1 as shown in the illustration.

28. Install the front LH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)








29. Install the front RH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.-lbf)

30. Install the front stabilizer link assembly LH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

NOTE: If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.








31. Install the front stabilizer link assembly RH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.-lbf)

32. Connect the steering gear outlet return tube.

A. Using the 17 mm Union nut wrench (or equivalent), connect the outlet return tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

HINT: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).









^ This torque wrench should be held as shown in the illustration.








B. Install the hose with the clip.

33. Connect the pressure feed tube assembly.








A. Install the pressure feed tube assembly to the frame sub-assembly with the 2 bolts.

Torque: 28 N.m (286 kgf.cm, 21 ft.-lbf)

B. Using the 17 mm Union nut wrench (or equivalent), tighten the flare nut and connect the pressure feed tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.-lbf)

NOTE: ^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).








^ This torque wrench should be held as shown in the illustration.








34. Install the steering intermediate shaft No. 2.

A. Align the matchmarks on the power steering gear assembly and steering intermediate shaft No. 2.

B. Install the steering intermediate shaft No. 2 to the power steering gear assembly with the bolt.

Torque: 36 N.m (360 kgf.cm, 27 ft.-lbf)


35. Install the steering sliding yoke.

A. Align the matchmarks on the steering column and steering slide yoke.

B. Install the steering sliding yoke to the steering column assembly and slide it upward.

C. Align the matchmarks on the intermediate shaft sub-assembly No. 2 and steering sliding yoke.

D. Install the sliding yoke to the intermediate shaft sub-assembly No. 2 with the bolt A and bolt B.

Torque: Bolt A, B: 36 N.m (370 kgf.cm, 27 ft.-lbf)


36. Connect the tie rod end sub-assembly LH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


37. Connect the tie rod end sub-assembly RH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.-lbf)


38. Install the engine under cover sub-assembly No. 1 with the 4 bolts.

39. Install the engine under cover assembly rear with the 6 bolts.

40. Install the front wheel.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.-lbf)

41. Place the front wheels facing straight ahead.

42. Add power steering fluid.

43. Bleed the power steering fluid.

A. Check the fluid level.

B. Ensure that the front of the vehicle is slightly higher than the rear of the vehicle to aid in air bleeding of the steering rack.

C. Turn the steering wheel. With the engine stopped, turn the wheel slowly from lock to lock several times.

D. Lower the vehicle.

E. Reconnect the negative (-) battery terminal.

F. Start the engine. Run the engine at idle for a few minutes.

G. Turn the steering wheel.

a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 to 3 seconds. Then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds.

b. Repeat step "a" several times.


H. Stop the engine.









I. Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

J. Check the fluid level.

44. Check the power steering fluid leakage.

45. Inspect and adjust the wheel alignment. Inspect the vehicle alignment using the instructions provided on the Technical Information System (TIS): 2003 or 2004 model year 4Runner Repair Manual: Front Suspension: Front Wheel Alignment: Adjustment.

46. Return to "Diagnostic Procedure", step 4, to continue procedure.

NOTE: Prior to returning the vehicle to the vehicle to the customer, re-initialize the power windows and moon roof. Refer to TSB No. PG021-02, "Back Door Power Window Initialization During PDS," and TSB No. EL009-04, "Power Window/Roof Initialization Procedures."

 

[admin]

#5
1. See the precaution in the Steering Rack Guide Spring Installation Procedure" of this TSB.

2. Place the front wheels facing straight ahead with the engine running.

3. Record the radio presets.

4. Turn the key to the OFF position and remove the keys from the ignition.

5. Disconnect the negative (-) battery terminal.

6. Remove the steering wheel cover lower No. 3.

7. Remove the steering wheel cover lower No. 2.

8. Remove the horn button assembly.

NOTE: If the airbag connector is disconnected with the ignition switch ON, DTCs will be recorded.








A. Using a Torx socket wrench (Torx socket wrench [T=30]), loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.

NOTE: When removing the horn button assembly, take care not to pull the airbag wire harness.







B. Pull out the horn button assembly from the steering wheel assembly.

C. Using a screwdriver, release the lock part of each of the airbag connectors and disconnect the 2 airbag connectors.

D. Disconnect the horn ground harness from the horn button assembly.








CAUTION: ^ When storing the horn button assembly, keep the upper surface of the pad facing upward.

^ Never disassemble the horn button assembly.

9. Remove the steering wheel assembly.

A. With steering pad switch: Disconnect the connector.

B. Remove the steering wheel assembly set nut.









C. Set the SST on the steering wheel assembly.

D. Remove the steering wheel assembly.

^ SST P/N: 09950-50013-01 (09951-05010, 09952-05010, 09953-05020, 09954-05020)


10. Install the steering wheel assembly.

A. Install the new steering wheel assembly with the steering set nut.

Torque: 50 N.m (510 kgf.cm, 37 ft.-lbf)

B. With steering pad switch: Connect the connector.


11. Install the horn button assembly.

NOTE: ^ Make sure the horn button assembly is installed to the specified torque.

^ If the horn button assembly has been dropped or there are cracks, dents, or other defects in the case of the connector, replace the horn button assembly with a new one.

^ When installing the horn button assembly, take care that the harness does not interfere with other parts and the wires are NOT pinched between other parts.









A. Connect the horn ground harness to the horn button assembly.

B. Connect the 2 airbag connectors.

C. Install the horn button assembly after confirming that the circumference groove of torx screw is caught on the screw case.

D. Using a torx socket wrench (Torx socket wrench [T=30]), torque the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in.-lbf)

12. Install the steering wheel cover lower No. 2.

13. Install the steering wheel cover lower No. 3.

14. Ensure that the front wheels are facing straight ahead.

15. Install the negative (-) battery terminal.

16. Inspect the SRS warning light.

17. Return to Diagnostic Procedure", step 4, to continue procedure.

NOTE: Prior to returning the vehicle to the vehicle to the customer, re-initialize the power windows and moon roof. Refer to TSB No. PG021-02, "Back Door Power Window Initialization During PDS," and TSB No. EL009-04, "Power Window/Roof Initialization Procedures."