Rack & Pinion Power Steering Gear Assembly: Overhaul

SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

1. Remove the cotter pin and nut.
2. Using SST, remove the tie rod assembly LH from the steering knuckle.

   SST 09628-62011

Fig 1: Disconnecting Tie Rod Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09628-62011

1. Loosen the bolt and remove the clamp from the steering column hole cover No. 1.
2. Disconnect the steering column hole cover No. 2 from the steering column hole cover No. 1.
3. Loosen the bolt.
   Fig 2: Disconnecting Steering Intermediate Shaft Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place matchmarks on the steering intermediate shaft sub-assembly and steering gear assembly.
5. Remove the bolt and separate the steering intermediate shaft sub-assembly.

Fig 3: Displaying Match Marks Placing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the nut and disconnect the front stabilizer link assembly from the absorber.
   NOTE: If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud.
   Fig 4: Disconnecting Front Stabilizer Link Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 5: Removing Front Stabilizer Bracket No. 1

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1. Using SST, disconnect the return tube assembly from the steering gear assembly.

   SST 09023-12700

   Fig 6: Disconnecting Pressure Feed Tube Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, disconnect the pressure feed tube assembly from the steering gear assembly.

   SST 09023-12700

   Fig 7: Using SST Disconnecting Pressure Feed Tube Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and disconnect the return feed tube clamp.
   Fig 8: Removing Nut

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1. Remove the bolt and disconnect the tube clamp.
   Fig 9: Removing Rack & Pinion Power Steering Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts, nuts and steering gear assembly.
   Fig 10: Locating Bolts & Nuts For Removal

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1. Remove the power steering rack housing heat insulator.

1. Using SST, remove the left turn pressure tube.

   SST 09023-38200

2. Remove the 2 O-rings from the left turn pressure tube.

1. Using SST, secure the steering gear assembly.

   SST 09023-38200

2. Remove the 2 O-rings from the right turn pressure tube.

Fig 11: Removing Steering Left Turn Press Tube

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, secure the steering gear assembly.

   SST 09612-00012

   NOTE: Tape the SST before use.
   Fig 12: Fixing Rack & Pinion Power Steering Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place matchmarks on the tie rod assembly LH and rack end.
2. Loosen the lock nut, and remove the tie rod assembly LH and lock nut.

Fig 13: Removing Tie Rod Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Secure the tie rod LH in a vise.
2. Install the nut to the stud bolt.
3. Flip the ball joint stud back and forth 5 times.
4. Using a torx wrench, turn the nut continuously at a rate of 2-4 seconds per one turn and take the torque reading of the 5th turn.

   Turning torque:  0.83-3.43 N.m (8.5-35.0 kgfcm, 7.3-30.4 in.lbf)

   Fig 14: Inspecting Tie Rod Assembly LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 steering rack boot clips.

1. Using pliers, remove the steering rack boot No. 2 clamp.
   NOTE: Be careful not to damage the steering rack boot.

1. Remove the steering rack boot No. 2.

1. Using a screwdriver and a hammer, unstake the claw washer.
   NOTE: Avoid any impact to the power steering rack.
   Fig 15: Removing Steering Rack End Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using 2 SSTs, remove the 2 rack ends and 2 claw washers.

   SST 09922-10010

Fig 16: Removing Rack Ends & Claw Washers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the rack guide spring cap nut.

   SST 09922-10010

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   Fig 17: Removing Rack Guide

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rack guide spring cap.

   SST 09631-10021

3. Remove the compression spring and rack guide.
   Fig 18: Removing Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 27 mm socket wrench, remove the rack housing cap.
   Fig 19: Removing Power Steering Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, hold the control valve shaft and remove the nut.

   SST 09616-00011

   Fig 20: Displaying Nut Removal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Wind vinyl tape around the serrated part of the control valve.
4. Remove the dust cover from the control valve housing.
   Fig 21: Locating Control Valve Serrated Part

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 bolts and control valve.
6. Remove the gasket.
   Fig 22: Locating Bolts For Removal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
8. Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
9. Remove the oil seal from the control valve.
   Fig 23: Winding Vinyl Tape For Protection

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a screwdriver, remove the 4 control valve rings.
    NOTE: Be careful not to damage the grooves for the control valve ring.
    Fig 24: Removing Control Valve Rings

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the control valve upper bearing and upper oil seal from the control valve housing. SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)

Fig 25: Removing Power Steering Control Valve Upper Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
2. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.

Fig 26: Removing Cylinder End Stopper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the power steering rack bush from the power steering rack.
2. Using SST, remove the rack bush oil seal.

   SST 09527-21011, 09612-24014 (09613-22011)

3. Using a screwdriver, remove the O-ring from the power steering rack bush.

Fig 27: Removing Power Steering Rack Bush

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a dial indicator, check the steering rack for runout and for teeth wear and damage.

   Maximum Runout:  0.3 mm (0.0118 in.)

2. Check the back surface for wear and damage.
   Fig 28: Inspection Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the power steering cylinder oil seal.

   SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)

   Fig 29: Removing Power Steering Cylinder Tube Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the rack steering piston ring and O-ring.
   NOTE: Be careful not to damage the grooves for rack steering piston ring.
   Fig 30: Removing Rack Steering Piston Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with power steering fluid and install it to the steering rack.
2. Expand a new rack steering piston ring with your fingers.
   NOTE: Be careful not to over expand the rack steering piston ring.
3. Coat a new rack steering ring with power steering fluid.
   Fig 31: Installing Rack Steering Piston Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the rack steering piston ring to the power steering rack, and settle it down with your fingers.

Fig 32: Installing Rack Steering Piston Ring

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1. Coat a new power steering cylinder tube oil seal lip with power steering fluid.

   SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360)

2. Using SST and a press, install the power steering cylinder tube oil seal.

Fig 33: Installing Power Cylinder Tube Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the power steering rack.

   SST 09631-33010

   NOTE: If necessary, scrape the burrs off the power steering rack teeth end and burnish.
2. Coat the SST with power steering fluid.
3. Install the power steering rack into the rack housing.
4. Remove the SST.

Fig 34: Installing Power Steering Rack

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, install the rack bush oil seal to the power steering rack bush.

   SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

   NOTE: Make sure that the rack bush oil seal is installed facing in the correct direction.
2. Coat a new O-ring with power steering fluid and install it to the power steering rack bush.
   Fig 35: Installing Power Steering Rack Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. To prevent rack bush oil seal lip damage, wind vinyl tape around the steering rack end, and apply power steering fluid.
4. Install the rack bush to the steering rack.

Fig 36: Winding Vinyl Tape Around Serrated Steering Rack End

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
2. Install a new wire into the cylinder end stopper.
3. Using a screwdriver, turn the cylinder end stopper clockwise by 450 +/- 50 degrees.

Fig 37: Installing Cylinder End Stopper

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   SST 09631-12071 (09633-00010)

2. Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds.
3. Check that there is no change in the vacuum.

   If there is a change in the vacuum, check the installation of the oil seals.

   Fig 38: Displaying Air Tightness Test

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a control valve upper bearing and a new upper oil seal with power steering fluid.
2. Using SST and a press, install the upper oil seal.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320)

   Fig 39: Installing Power Steering Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the control valve upper bearing.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)

   Fig 40: Installing Control Valve Upper Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Expand 4 new valve rings with your fingers.
   NOTE: Be careful not to over expand the valve ring.
2. Coat the 4 valve rings with power steering fluid.
3. Install the 4 valve rings to the control valve, and settle them down with your fingers.
   Fig 41: Installing Power Steering Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Carefully slide the tapered end of SST over the valve rings until they fit to the control valve.

   SST 09631-20081

   NOTE: Be careful not to damage the valve rings.
   Fig 42: Locating Valve Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. To prevent upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
6. Coat the upper oil seal lip with power steering fluid.
7. Install the control valve to the control valve housing.
   NOTE: Be careful not to damage the control valve ring and upper oil seal lip.
   Fig 43: Winding Vinyl Tape Around Control Valve Serrated Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Coat a new oil seal lip with power steering fluid.
9. Using SST and a press, install the oil seal.

   SST 09612-22011

   NOTE: Make sure that the oil seal is installed facing in the correct direction.
   Fig 44: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Apply grease to the needle bearing.
11. Install a new gasket to the valve housing.
12. Wind vinyl tape around the serrated part of the control valve.
13. Install the valve housing to the rack housing with the 2 bolts.

    Torque:  21 N.m (214 kgf.cm, 15 ft.lbf)

    Fig 45: Locating Valve Housing Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Using SST, stop the control valve shaft rotation and install a new lock nut.

    Torque:  24.5 N.m (250 kgf.cm, 18 ft.lbf)

    SST 09616-00011

15. Apply sealant to 2 or 3 threads of the rack housing cap.

    Sealant:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

    Fig 46: Installing New Lock Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. Using a 27 mm socket wrench, install the rack housing cap.

    Torque:  58.5 N.m (597 kgf.cm, 43 ft.lbf)

    Fig 47: Installing Rack Housing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Using a punch and a hammer, stake the rack housing cap and rack housing.

Fig 48: Staking Rack Housing Cap & Rack Housing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply molybdenum disulfide lithium base grease to the rack guide.
2. Install the rack guide.
3. Install the compression spring.
4. Apply sealant to 2 or 3 threads of the rack guide spring cap.

   Sealant:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.

5. Temporarily install the rack guide spring cap.

1. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
2. Using SST, torque the rack guide spring cap.

   SST 09631-10021

   Torque:  25 N.m (255 kgf.cm, 18 ft.lbf)

   Fig 49: Adjusting Total Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, loosen the rack guide spring cap.

   SST 09631-10021

   Fig 50: Loosening Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft to the right and left 1 or 2 times.

   SST 09616-00011

5. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning.

   SST 09631-10021

   Fig 51: Locating Control Valve For Loosening

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.

   SST 09616-00011, 09631-10021

   Preload (turning):  1.2-1.5 N.m (12.2-15.3 kgf.cm, 10.6-13.3 in.lbf)

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

   Sealant:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

8. Temporarily install the rack guide spring cap nut.
   Fig 52: Tightening Rack Guide Spring Cap Within Specifications

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap nut.

   SST 09616-00011, 09922-10010

   Torque:  48 N.m (489 kgf.cm, 35 ft.lbf)

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

10. Precheck the total preload.

    Preload (turning):  1.2-1.5 N.m (12.2-15.3 kgf.cm, 10.6-13.3 in.lbf)

11. Remove the RH and LH rack ends.
    Fig 53: Using Specified SST For Rack Ends Removal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Apply MP grease into the control valve, as shown in the illustration. See Fig 54.
    Fig 54: Applying MP Grease Into Control Valve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Wind vinyl tape around the serrated part of the control valve.
14. Install the dust cover to the control valve housing.
    Fig 55: Winding Vinyl Tape Around Serrated Part Of Control Valve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new 2 claw washers, and temporarily install the 2 rack ends.
   NOTE: Align the claws of the claw washer with the steering rack grooves.
2. Using 2 SSTs, install the 2 rack ends.

   SST 09922-10010

   Torque:  58.5 N.m (597 kgf.cm, 43 ft.lbf)

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   NOTE:

   • Using SST, hold the rack and install the rack end.
   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   Fig 56: Installing Steering Rack End Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, stake the claw washer.
   NOTE: Avoid any impact to the steering rack.
   Fig 57: Staking Claw Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Ensure that the steering rack end hole is not clogged with grease.
   NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.
   Fig 58: Inspecting Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the steering rack boot No. 2.

1. Using SST, tighten the steering rack boot No. 2 clamp, as shown in the illustration.

   SST 09521-24010

   Clearance:  3.0 mm (0.118 in.) or less

   NOTE: Be careful not to damage the boot.

Fig 59: Installing Steering Rack Boot No. 2 Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09521-24010

1. Using pliers, install the 2 rack boot clips.

1. Screw the lock nut and tie rod assembly LH onto the rack end until the matchmarks are aligned.
   NOTE: After adjusting toe-in, torque the lock nut.

1. Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
2. Using SST, install the left turn pressure tube to the steering gear assembly.

   SST 09023-38200

   Torque:  11.5 N.m (117 kgf.cm, 8 ft.lbf)

Fig 60: Installing Steering Left Turn Pressure Tube

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube.
2. Using SST, install the right turn pressure tube to the steering gear assembly.

   SST 09023-38200

   Torque:  11.5 N.m (117 kgf.cm, 8 ft.lbf)

Fig 61: Installing Steering Right Turn Pressure Tube

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the power steering rack housing heat insulator.

1. Install the power steering gear assembly with the 2 bolts and nuts.

   Torque:  70 N.m (714 kgf.cm, 52 ft.lbf)

   Fig 62: Installing Rack & Pinion Power Steering Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the pressure feed tube assembly clamp with the bolt.

   Torque:  9.8 N.m (100 kgf.cm, 87 in.lbf)

   Fig 63: Connecting Pressure Feed Tube Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, connect the pressure feed tube assembly to the steering gear.

   SST 09023-12700

   Torque:  22.5 N.m (229 kgf.cm, 17 ft.lbf)

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.
   Fig 64: Connecting Pressure Feed Tube Assembly To Steering Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, connect the return tube assembly to the steering gear.

   SST 09023-12700

   Torque:  22.5 N.m (229 kgf.cm, 17 ft.lbf)

   NOTE:

   • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.
   Fig 65: Connecting Return Turn Assembly To Steering Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the return tube clamp with the nut.

   Torque:  9.8 N.m (100 kgf.cm, 87 in.lbf)

   Fig 66: Installing Return Tube Clamp With Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the front stabilizer bracket No. 1 LH with the 2 bolts.

   Torque:  19 N.m (194 kgf.cm, 14 ft.lbf)

   Fig 67: Installing Front Stabilizer Bracket No. 1 LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the stabilizer link assembly LH to the stabilizer bar with the nut.

   Torque:  74 N.m (755 kgf.cm, 55 ft.lbf)

   NOTE: If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud.
   Fig 68: Connecting Front Stabilizer Link Assembly LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the matchmarks on the intermediate shaft sub-assembly and steering gear assembly.
2. Install the bolt.

   Torque:  35.3 N.m (360 kgf.cm, 26 ft.lbf)

   Fig 69: Displaying Intermediate Shaft Sub-Assembly Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the bolt.

   Torque:  35.3 N.m (360 kgf.cm, 26 ft.lbf)

4. Install the steering column hole cover No. 2 to the steering hole cover No. 1.
5. Connect the clamp to the steering column hole cover No. 1 and tighten the bolt.

Fig 70: Locating Bolts For Tightening

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the tie rod assembly LH with the nut.

   Torque:  49 N.m (500 kgf.cm, 36 ft.lbf)

2. Install a new cotter pin.

Torque:  103 N.m (1,050 kgf.cm, 76 ft.lbf)