Steering Shaft - Upper

This procedure covers removal and replacement of the upper steering shaft on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including disconnection from the lower steering shaft and steering column.

Warnings

Tools required

Parts

• Upper steering shaft assembly × 1 — Use OEM specification
• Steering shaft pinch bolt (if not reusable) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and set parking brake
2. Ensure front wheels are pointing straight ahead
3. Disconnect negative battery terminal and wait 90 seconds minimum
4. Remove driver's side knee airbag panel if equipped for better access
5. Remove lower steering column covers

Procedure

1. 1

   Remove lower steering column covers
   Remove the upper and lower steering column covers by releasing the retaining clips and removing the cover screws. The lower cover typically has 2-3 screws accessible from underneath. Carefully separate covers and set aside.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Access upper steering shaft
   Position yourself in the driver's footwell with adequate lighting. Locate the upper steering shaft where it connects to the lower intermediate shaft below the steering column. You may need to remove or lower the knee bolster panel for better access.
3. 3

   Mark shaft alignment
   Using a center punch or paint marker, mark the relationship between the upper steering shaft and lower intermediate shaft at the universal joint. Make clear alignment marks on both shafts at the same position. This ensures proper reassembly and maintains steering wheel center position.
   ⚠Failure to mark alignment will result in an off-center steering wheel after reassembly.
4. 4

   Remove lower shaft pinch bolt
   Locate the pinch bolt that secures the upper steering shaft to the lower intermediate shaft at the universal joint coupling. Apply penetrating oil if needed. Remove the pinch bolt completely using the appropriate socket. The bolt typically has a 12mm or 14mm head. Support the lower shaft to prevent it from dropping.
5. 5

   Disconnect upper shaft from lower shaft
   Carefully separate the upper steering shaft from the lower intermediate shaft by pulling them apart at the universal joint. You may need to use a flathead screwdriver to gently pry the coupling apart. Do not use excessive force. Once separated, secure the lower shaft to prevent it from rotating.
6. 6

   Remove steering column mounting bolts
   Locate the mounting bolts that secure the steering column assembly to the dash support bracket. There are typically 2-4 bolts. Remove these mounting bolts while supporting the steering column. Note the position of any spacers or alignment shims.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Disconnect electrical connectors
   Disconnect all electrical connectors from the steering column assembly including clockspring connector, ignition switch connector, and any other wiring harnesses. Press the release tabs and carefully pull connectors straight off. Note the routing of wiring for reassembly.
8. 8

   Remove upper steering shaft assembly
   With all connections disconnected and bolts removed, carefully lower and remove the steering column and upper steering shaft assembly from the vehicle. Work carefully to avoid damaging the clockspring or other components. The assembly may need to be tilted or rotated slightly to clear the dash opening.
9. 9

   Install new upper steering shaft
   Position the new upper steering shaft assembly into the vehicle, aligning it with the mounting bracket. Ensure the shaft is oriented correctly and the clockspring is centered. Route all wiring harnesses in their original positions. Install mounting bolts finger-tight initially.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Connect electrical connectors
    Reconnect all electrical connectors to the steering column assembly. Ensure each connector clicks into place securely. Verify clockspring connector is fully seated and locked.
11. 11

    Reconnect upper and lower shafts
    Align the marks made during disassembly on the upper and lower steering shafts. Slide the upper shaft into the lower intermediate shaft coupling until fully seated. Verify alignment marks are properly matched. Install the new pinch bolt and tighten to specification. If torque specification is not provided in your service manual, typical specification is 25-30 Nm (18-22 lb-ft), but verify with manufacturer documentation.
12. 12

    Reinstall steering column covers
    Reinstall the lower and upper steering column covers. Align all clips and tabs properly. Install and tighten cover screws to specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reinstall knee bolster panel and any other trim pieces removed during disassembly
2. Reconnect battery negative terminal
3. Perform steering wheel centering verification before test drive

Verification

• Turn ignition to ON position and verify no airbag warning lights remain illuminated after system check completes (approximately 6 seconds)
• Start engine and verify power steering functions normally without warning lights
• With engine running, turn steering wheel lock-to-lock slowly and verify smooth operation with no binding, clicking, or unusual noises
• Verify steering wheel is centered when front wheels are pointing straight ahead
• Test drive vehicle at low speed in safe area to confirm normal steering operation and proper wheel alignment
• Check that all steering column functions operate correctly (tilt, telescope, turn signals, wipers, cruise control)

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