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Power Steering Gear: Reassembly

CAUTION: When using a vise, do not overtighten it.
  1. Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease. See POWER STEERING GEAR .
  2. Install oil seal.
    1. Coat a new oil seal lip with power steering fluid.
    2. Using SST, press in the oil seal.
        Fig 1: Pressing In New Oil Seal With SST
        G01148664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)
      CAUTION:
      • Make sure that the oil seal is installed facing in the correct direction.
      • Take care that the oil seal does not get reversed as you install it.
  3. Install steering rack.
    1. Install SST to the steering rack.
        Fig 2: Installing SST To Steering Rack
        G01148665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09631-20102
      NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
    2. Coat SST with power steering fluid.
    3. Install the steering rack into the rack housing.
      CAUTION: Be careful not to damage the oil seal lip.
    4. Remove the SST.
      1. SST 09631-20102
  4. Install oil seal.
    1. Coat a new oil seal lip with power steering fluid.
    2. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
      Fig 3: Installing Oil Seal Into Rack Housing
      G01148666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil seal by pushing it into the rack housing without tilting.
      CAUTION:
      • Make sure that the oil seal is installed facing in the correct direction.
      • Be careful not to damage the oil seal lip.
  5. Install cylinder end stopper.
    1. Using SST and a hammer, drive in the cylinder end stopper.
      Fig 4: Driving In Cylinder End Stopper With SST & Hammer
      G01148667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09612-22011

    2. Using snap ring pliers, install the snap ring to the rack housing.
  6. Air tightness test.
    1. Connect the 2 SSTs as shown in Fig 5.
      Fig 5: Connecting SSTs
      G01148668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09631-12071, 09631-22030

    2. Install connected SSTs to the rack housing.
      Fig 6: Installing SST To Rack Housing
      G01148669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
    4. Check that there is no change in the vacuum.
      1. If there is change in the vacuum, check the installation of the oil seals.
  7. Install control valve assembly.
    1. Coat the teflon rings of the control valve assembly with power steering fluid.
    2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
      Fig 7: Installing Control Valve Assembly
      G01148670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the control valve assembly into the control valve housing.
      CAUTION: Be careful not to damage the teflon rings and oil seal.
  8. Install control valve housing.
    1. Coat a new O-ring with power steering fluid and install it to the control valve housing.
    2. Using a 6 mm hexagon wrench, install the control valve housing with the 2 bolts.
      1. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
  9. Install dust cover.
  10. Install bearing and spacer.
    1. Install the spacer and a new bearing to the rack housing.
  11. Install self-locking nut.
    1. Using SST, stop the control valve shaft rotating and install a new self-locking nut.
      1. SST 09616-00011
      2. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf)
      Fig 8: Installing Self-Locking Nut With SST
      G01148671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Install rack housing cap.
    1. Apply sealant to 2 or 3 threads of the rack housing cap.
      1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
    2. Install the rack housing cap.
      1. Torque: 69 N.m (700 kgf.cm, 51 ft.lbf)
  13. Install rack guide sub-assembly, rack guide spring and rack guide spring cap.
    1. Install the rack guide sub-assembly and rack guide spring.
    2. Apply sealant to 2 or 3 threads of the rack guide spring cap.
      1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
    3. Temporarily install the rack guide spring cap.
  14. Adjust total preload.
    1. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
    2. Using a 24 mm hexagon wrench, torque the rack guide spring cap.
      1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
    3. Using a 24 mm hexagon wrench, return the rack guide spring cap 12 degrees.
      4. Fig 9: Tightening Rack Guide Spring Cap
      G01148672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.
        Fig 10: Turning Control Valve Shaft Right & Left With SST
        G01148673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09616-00011
    5. Using a 24 mm hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning.
    6. Using SST, a torque wrench and a 24 mm hexagon wrench, tighten the rack guide spring cap until the preload is within specifications.
      1. SST 09616-00011
      2. Preload (turning): 0.8-1.6 N.m (8-16 kgf.cm, 7.0-13.9 in.lbf)
      Fig 11: Tightening Rack Guide Spring Cap Lock Nut With SST
      G01148674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install rack guide spring cap lock nut.
    1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
      1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
    2. Temporarily install the rack guide spring cap lock nut.
    3. Using a 24 mm hexagon wrench, hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
        Fig 12: Installing Rack Guide Spring Cap Lock Nut
        G01148675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09922-10010
      2. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
        NOTE:
        • Use SST 09922-10010 in the direction shown in Fig 12.
        • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
    4. Recheck the total preload.
      1. Preload (turning): 0.8-1.6 N.m (8-16 kgf.cm, 7.0-13.9 in.lbf)
    5. Remove the RH and LH rack ends.
  16. Install RH and LH claw washers and rack ends.
    1. Install a new claw washer, and temporarily install the rack end.
      NOTE: Align the claws of the washer with the steering rack grooves.
    2. Using a wrench, hold the steering rack steadily and using SST, torque the rack end.
        Fig 13: Installing Rack End To Steering Rack
        G01148676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09922-10010
      2. Torque: 95 N.m (970 kgf.cm, 70 ft.lbf)
        NOTE:
        • Use SST 09922-10010 in the direction shown in Fig 13.
        • Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
    3. Using a brass bar and hammer, stake the washer.
      Fig 14: Staking Washer With Brass Bar & Hammer
      G01148677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Avoid any impact on the steering rack.
    4. Employ the same manner described in line  c to the other side.
  17. Install RH and LH rack boots, clamps and clips.
    1. Ensure that the steering rack hole is not clogged with grease.
      Fig 15: Identifying Steering Rack Hole
      G01148678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
    2. Install the boot, clip and clamp.
      CAUTION: Be careful not to damage or twist the boot.
    3. After winding and tightening the wire around the circumference of the boot twice, twist it several times, and install it.
      Fig 16: Displaying Tightened & Twisted Wire
      G01148679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. As shown in Fig 17, bend the wire to the circular direction to prevent damage to the boot.
      Fig 17: Bending Wire Back Against Boot
      G01148680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Employ the same manner described on line  d to the other side.
  18. Install RH and LH tie rod ends and lock nuts.
    1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
      Fig 18: Identifying Matchmarks On Rack
      G01148681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. After adjusting toe-in, torque the nut.
      1. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf)
    3. Employ the same manner described on line  b to the other side
  19. Install pressure control valve.
    1. Coat 4 new O-rings with power steering fluid and install them to the pressure control valve.
    2. Using hexagon wrench (6 mm), install the pressure control valve with the 3 bolts.
      Fig 19: Identifying Bolts For Installation
      G01148682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)

  20. Install 2 turn pressure tubes.
    1. Using SST, connect the turn pressure tube.
        Fig 20: Installing Turn Pressure Tubes
        G01148683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09023-38200
      2. Torque: 23 N.m (235 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 case that SST is parallel to a torque wrench.
    2. Install the 2 turn pressure tubes and 6 gaskets with the 3 bolts.
      1. Torque: 34 N.m (350 kgf.cm, 25 ft.lbf)
    3. Install the tube clamp.
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