Power Steering Gear: Reassembly

1. Coat a new oil seal lip with power steering fluid.
2. Install the oil seal to SST, and press them into the rack housing.
   1. SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951- 07360)
   NOTE:

   • Make sure that the oil seal is installed facie in the correct direction.
   • Take care that the oil seal does not get reversed as you install it.
   Fig 1: Install Oil Seal To SST, And Press Them Into Rack Housing

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1. Install SST to the steering rack.
   1. SST 09631-33010

   HINT:

   If necessary, scrape the burrs off the steering rack teeth end and burnish.

2. Coat the SST with power steering fluid.
3. Install the steering rack into the rack housing.
4. Remove the SST.
   1. SST 09631-3301
   Fig 2: Installing Steering Rack Into Rack Housing

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1. Coat a new O-ring with power steering fluid and install it to the bushing
2. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
3. Install the bushing.

Fig 3: Installing Bushing

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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 SST, turn the cylinder end stopper clockwise 450 +/- 50°.
   1. SST 09631-10021
   Fig 4: Installing Cylinder End Stopper

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1. Install the SST to the rack housing.
   1. SST 09631-12071
2. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum 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 5: Performing Air Tightness Test

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1. Install the rack housing No. 2 grommet to the rack housing No. 2 bracket.

   HINT:

   Align the projection of the grommet with the hole of the rack housing No. 2 bracket.

2. Align the matchmarks on the rack housing No. 2 bracket and rack housing.
   Fig 6: Installing Rack Housing No. 2 Bracket And Grommet

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3. Place the rack housing No. 2 bracket in a vise and tighten the vise to fasten the clamp.
   Fig 7: Tightening Vise To Fasten The Clamp

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1. To prevent oil seal lip damage, wind vinyl tape on the serrated pair of the control valve shaft.
2. Coat the teflon rings with power steering fluid.
3. Install the control valve assembly into the control valve housing.
   NOTE: Be careful not to damage the teflon rings and oil seal lip.
   Fig 8: Installing Control Valve Assembly

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1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
   1. SST 09612-22011
   NOTE: Make sure that the oil seal is installed facing in the correct direction.

1. Place a new gasket on the rack housing.
2. Align the matchmarks on the control valve housing and rack housing.
3. Install the 2 bolts.
   1. Torque: 18 N.m (180 kgf.cm, 13 ft.Ibf) 

Using SST, stop the control valve shaft rotating and install a new self-locking nut.

1. SST 09616-00011
2. Torque: 25 N.m (250 kgf.cm, 18 ft.Ibf) 
Fig 10: Installing Self-Locking Nut
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1. Apply sealant, to 2 or 3 threads of the cap.

   Sealant: 

   1. Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Install the rack housing cap.
   1. Torque: 59 N.m (600 kgf.cm, 43 ft.Ibf) 
3. Using a punch and a hammer, stake the 2 parts of the rack housing cap.
   Fig 11: Staking Parts Of Rack Housing Cap

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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.

   Sealant: 

   1. Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalent 
3. 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.
   1. SST 09631-10021
   2. Torque: 25 N.m (250 kgf.cm, 18 ft.Ibf) 
   Fig 12: Tightening Rack Guide Spring Cap

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3. Using SST, return the rack guide spring cap 12°.
   1. SST 09631-10021
   Fig 13: Returning Rack Guide Spring Cap

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4. Using SST, turn the control valve shaft right and left 1 or 2 times.
   1. SST 09616-00011
5. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning.
   1. SST 09631-10021
   Fig 14: Loosening Rack Guide Spring Cap

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6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
   1. SST 09616-00011, 09631-10021
   2. Preload (turning): 0.8 -1.4 N.m (8 -14 kgf.cm, 6.9 -12.2 in.lbf) 
   Fig 15: Using SST And A Torque Wrench, Tighten Rack Guide Spring Cap

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

   Sealant: 

   1. Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Temporarily install the rack guide spring cap lock nut.
3. Using SST, hold the rack guide spring cap and using another SST, torque the rack guide spring cap lock nut.
   1. SST 09631-10021, 09922-10010
      NOTE: Use SST 09922-10010 in the direction shown in the illustration.
      Fig 16: Installing Rack Guide Spring Cap Lock Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

4. Recheck the total preload.
   1. Preload (turning): 0.8-1.4 N.m (8-14 kgf.cm, 6.9-12.2 in.lbf) 
5. Remove the RH and LH rack ends.

1. Install a new claw washer, and temporarily install the rack ends.

   HINT:

   Align the claws of the claw washer with the steering rack grooves.

   Fig 17: Installing New Claw Washer

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2. Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end.
   1. SST 09922-10010
   2. Torque: 60 N.m (610 kgf.cm, 44 ft.lbf) 
   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   HINT

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

   Fig 18: Using Torque Wrench With Fulcrum Length Of 345 Mm

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3. Using a brass bar and a hammer, stake the claw washer.
   NOTE: Avoid any impact to the steering rack
4. Employ the same manner described above to the other side.
   Fig 19: Using Brass Bar And Hammer, Stake Claw Washer

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1. Ensure that the steering rack hole is not clogged with grease.

   HINT:

   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 rack boot, clip and a new clamp.
   NOTE: Be careful not to damage or twist the boot.
   Fig 20: Ensuring That Steering Rack Hole Is Not Clogged With Grease

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3. Using SST, tighten the clamp as shown in the illustration.
   1. SST 09521-24010
4. Employ the same manner described above to the other side.

Fig 21: Using SST, Tighten Clamp

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

   (See FRONT WHEEL ALIGNMENT )

   1. Torque: 74 N.m (750 kgf.cm, 54 ft.Ibf) 
3. Employ the same manner described above to the other side.

1. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
2. Using SST, install the 2 turn pressure tubes.
   1. SST 09023-38200
   2. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

   HINT:

   • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
   • This torque value is effective in case that SST is parallel to a torque wrench.
   Fig 22: Using SST, Installing 2 Turn Pressure Tubes

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