REACH Motor Removal Hybrid Way 2003 XK8

Tools: T30 Torx (+ short ext 1/4" drive), 8mm Driver,10mm combo wrench, side cutters for wire ties, 2 wire ties, Pozi (PZ2) Drive Screwdriver, Metric Allen? for 2 hex holding column to Bulkhead , 13mm combo wrench, (Rear nuts on Allen) 15mm socket ( steering wheel), Small telescoping magnet, JIC, DRIVE CABLE. Possible Substitute is 3/16" rod with 95mm to 97mm L. with .75" square indexed ends

Move Tilt/RETRACT Switch to MANUAL from Auto. Drop column by removing Bolster, Cowlings and trim from around gauges. Next remove the two Allen Bolts and nuts at the bulkhead of the column up by the steering wheel end of the column .The column reach motor (Cable end mounts on front end facing wheel. Rear (Brown Pot) faces the Firewall [and is held to the steering column by a large black plastic clip, During removal, we used a flat screwdriver to pry one side of the clip loose and this we learned from a previous thread on this subject. ( see next thread for re-install). Prior to install, place cable into column to insure correct fit. Then place cable into motor drive to again test fit. The black plastic clamp that holds the motor in place, just pops off the column. and since the cable drive is normally what breaks gets remove all the pieces out of the gear drive in the column. (SEE IMPORTANT TIP BELOW) On install snap the black plastic clip into place after aligning cable to motor ? "May not be easy as you need to align the cable at both ends and this "clipping in sideways" motion is not conducive to getting the cable keyed at both ends."

IMPORTANT TIP--It is easier to slide the motor and the black piece of plastic
sleeve on the steering columns axis for removal or installation. This allows the new cable to key at both ends and the black plastic piece slides along the column and then snaps right in to place. C.W. is Retract and C.C.W. is Extend on column screw drive.

The column reach motor does have a potentiometer on one end and this is used to electronically set the stops for the retraction and reach limits, along with finding the memorized locations. It is important that you set the motors potentiometer properly before reinstalling, if you don't, there's a possibility of shearing the new cable. Being that my column was in the "in" position, We needed to set my potentiometer accordingly and my solution is as follows.

"According to the 1997 Range Electrical Guide, the Column Reach Motor Potentiometer Feedback is .5 volts (Out) and 4 volts (in)". Since our column was in the "retract " position, we spun the potentiometer with the unattached drive and motor plugged into harness until we got the lowest Ohm reading possible. Using 20k Ohm setting on DVM, (The 2003 XK8 reading was .69 at retract and 6.0+ ohms at extend). The Ohm reading was taken from the Blue wire and the Blue & White wire coming off of the potentiometer female connector (Yellow) . Once the motor was in Full Retract, we moved to the WHITE screw end between the 2 Allen bolts. Photo Incl. Using a nut driver with 8mm socket and latex glove as friction to hold head of screw, it was moved 1 complete turn in C.C.W. direction to move off Mechanical Stop on column.

A. With the Reach Cable still dislodged so the Reach Motor can run freely. Now place the Auto On/Off switch in the Auto position. Remove the key. The motor will spin and continue to spin to the fully retracted automatic stop
position.

B. On install pull the cable out of the motor and insert in column, then work the motor onto the cable. The fun part is getting the new motor to snap down on the column. You will notice a slot on each side of the black plastic holder with a notch in the middle. This has to fit into the recesses on the column. once you installed, operate it in and out to make sure works correctly and reinstall everything .
Following Thread INSTALL Steps #2



Column Down after 2 Allens loose

 

Thank you Kelly.
That needs to go in the DIY threads, you could not explain it much better.
Hope you body could stand the moving around.

 

RESOLVED We have completed the repair and all is functioning as it should.

 

Well done....