Power Steering Link: Reassembly

1. Coat a new O-ring with power steering fluid and install it to the steering rack.
2. Expand the new power piston oil seal with your fingers.
   NOTE: Be careful not to expand the oil seal excessively.
3. Coat the power piston oil seal with power steering fluid.
   Fig 1: Expanding And Coating Power Piston Oil Seal With Power Steering Fluid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the power piston oil seal to the steering rack, and adjust it with your fingers.

1. Apply power steering fluid to the lip of a new power steering cylinder tube oil seal.
2. Install the power steering cylinder tube oil seal to the rack housing at a slant.
   Fig 2: Installing Power Steering Cylinder Tube Oil Seal To Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, insert the power steering cylinder tube oil seal by pushing the SST in by hand until the oil seal passes the 2 ports.

   SST 09950-70010 (09951-07360), 09631-00200 

   NOTE:

   • Ensure that the power steering cylinder tube oil seal is installed in the correct direction as shown in the illustration.
   • Install the power steering cylinder tube oil seal at an angle of approximately 15° so that the lowermost part comes to the point, indicated by the arrow in the illustration, to prevent damage to the side of the oil seal when it passes the 2 ports.
   • Do not turn the SST when inserting the oil seal.
     Fig 3: Inserting Power Steering Cylinder Tube Oil Seal

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install SST (09631-00200) to SST (09951-07360) upside down.
5. Using SST, level the power steering cylinder tube oil seal by pushing the SST in by hand. Using SST and a press, install the oil seal.

   SST 09950-70010 (09951-07360), 09631-00200 

   Fig 4: Installing Power Steering Rack Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply molybdenum disulfide lithium base grease to the rack teeth ends.
2. Connect SST to the power steering rack sub-assembly.

   SST 09631-33010 

3. Coat SST with power steering fluid.
Fig 5: Connecting SST To Power Steering Rack Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the power steering rack sub-assembly to the power steering rack housing.
5. Remove SST.

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

   SST 09950-70010 (09951-07100), 09950-60010 (09951-00400, 09951-00250, 09952-06010) 

   NOTE: Ensure that the rack bushing oil seal is installed in the correct direction as shown in the illustration.
Fig 6: Installing Rack Bushing Oil Seal To Power Steering Rack Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat a new O-ring with power steering fluid and install it to the rack bushing.
3. Coat the rack bushing oil seal lip with power steering fluid.
4. Install the power steering rack bushing to the power steering rack housing.
   NOTE: Do not damage the rack bushing oil seal.

   HINT:

   Wrap protective tape around the end of the steering rack in order to prevent damage to the rack bushing oil seal.

   Fig 7: Installing Power Steering Rack Bushing To Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the cylinder end stopper to the power steering rack housing.
   Fig 8: Installing Cylinder End Stopper To Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using needle nose pliers, install the cylinder end stopper hole snap ring to the power steering rack housing.
   NOTE:

   • Make sure that the cylinder end stopper hole snap ring is securely installed in the power steering rack housing groove.
   • Make sure that the cylinder end stopper hole snap ring claws are aligned with the cylinder end stopper notch.
     Fig 9: Removing Power Steering Rack Sub-Assembly

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the power steering rack housing.

   SST 09631-12071 (09633-00010) 

   Fig 10: Installing SST To Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a vacuum of 53 kPa (398 mmHg, 15.65 in.Hg) for approximately 30 seconds.
3. Check that there is no change in the vacuum pressure.

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

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

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

   NOTE: Make sure that the power steering control valve upper oil seal is installed in the correct direction as shown in the illustration.
   Fig 11: Installing Power Steering Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the power steering control valve upper bearing with molybdenum disulfide lithium base grease.
2. Using SST and a press, press in the power steering control valve upper bearing.

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

   NOTE: Make sure that the power steering control valve upper bearing is installed in the correct direction as shown in the illustration.
   Fig 12: Pressing In Power Steering Control Valve Upper Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Expand 4 new power steering control valve spacers with your fingers.
   NOTE: Be careful not to expand the power steering control valve spacers excessively.
2. Coat the 4 power steering control valve spacers with power steering fluid.
   Fig 13: Expanding And Coating Power Piston Oil Seal With Power Steering Fluid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 power steering control valve spacers to the control valve, and adjust them with your fingers.

Fig 14: Installing And Adjusting The 4 Power Steering Control Valve Spacers To Control Valve With Fingers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the power steering control valve sub-assembly with power steering fluid.
2. Install the power steering control valve sub-assembly into the control valve housing sub-assembly.
   NOTE: Be careful not to damage the power steering control valve spacers and power steering control valve upper oil seal lip.

   HINT:

   Wrap protective tape around the spline of the power steering control valve sub-assembly in order to prevent damage to the oil seal.

   Fig 15: Installing Power Steering Control Valve Sub-Assembly Into Control Valve Housing Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new power steering control valve lower oil seal lip with power steering fluid.
2. Using SST and a press, install the power steering control valve lower oil seal to the control valve assembly.

   SST 09612-22011 

   NOTE:

   • Make sure that the power steering control valve lower oil seal is installed in the correct direction as shown in the illustration.
   • Do not damage the power steering control valve lower oil seal.
     Fig 16: Installing Power Steering Control Valve Lower Oil Seal To Control Valve Assembly

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the power steering control valve assembly and a new gasket to the power steering rack housing with the 2 bolts.

   Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf) 

   Fig 17: Locating Power Steering Control Valve Assembly Bolts

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

   SST 09616-00011 

   Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

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

   Sealant: 

   TOYOTA genuine adhesive 1344, THREE BOND 1344 or equivalent 

   Fig 18: Holding Control Valve Shaft Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a socket wrench (27 mm (1.06 in.)), install the rack housing cap.

   Torque: 54 N*m (546 kgf*cm, 40 ft.*lbf) 

   Fig 19: Installing Rack Housing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a punch and a hammer, stake the rack housing cap and the power steering rack housing.
   Fig 20: Staking Rack Housing Cap And Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with molybdenum disulfide lithium base grease and install it to the rack guide spring cap.
2. Apply molybdenum disulfide lithium base grease to the rack guide base and rack guide.
   Fig 21: Locating O-Ring From Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rack guide base to the rack guide.
4. Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide sub-assembly and the power steering rack.
   Fig 22: Identifying Rack Guide Base From Rack Guide

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the compression spring and rack guide sub-assembly to the power steering rack housing.
   Fig 23: Identifying Compression Spring And Rack Guide Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a straight hexagon wrench (24 mm (0.94 in.)), install the rack guide spring cap to the power steering rack housing.

   Torque: 50 to 70 N*m (514 to 714 kgf*cm, 37 to 52 ft.*lbf) 

   Fig 24: Installing Rack Guide Spring Cap To Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, turn the control valve and measure the turning torque.

   Torque: 6.0 N*m (61 kgf*cm, 54 in.*lbf) or more 

   Fig 25: Measuring Turning Torque

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Put matchmarks [a] on the power steering rack housing and the rack guide spring cap.
   Fig 26: Putting Matchmarks On Power Steering Rack Housing And Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Put matchmarks [b] 30° counterclockwise from matchmarks [a] on the power steering rack housing.
   Fig 27: Putting Matchmarks Counterclockwise From Matchmarks On Power Steering Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a straight hexagon wrench (24 mm (0.94 in.)), loosen the rack guide spring cap until matchmarks [b] and matchmarks [a] on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap.

    Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) or more 

    Fig 28: Measuring Rotating Torque

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. If the rotating torque required when loosening is below the specified value, perform the following procedure to achieve the specified value.
    1. Using a straight hexagon wrench (24 mm (0.94 in.)), re-tighten the rack guide spring cap.

       Torque: 50 to 70 N*m (510 to 714 kgf*cm, 37 to 52 ft.*lbf) 

       Fig 29: Installing Rack Guide Spring Cap To Power Steering Rack Housing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a punch and hammer, stake the power steering rack housing and rack guide spring cap at 3 equally spaced positions.

       HINT:

       Tap the power steering rack housing and rack guide spring cap strongly and repeatedly to stake them securely.

       Fig 30: Staking Power Steering Rack Housing And Rack Guide Spring Cap

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a straight hexagon wrench (24 mm (0.94 in.)), loosen the rack guide spring cap until matchmarks [b] and matchmarks [a] on the rack guide spring cap are aligned. Measure the rotating torque required when loosening the rack guide spring cap.

       Torque: 10 N*m (102 kgf*cm, 7.4 ft.*lbf) or more 

       Fig 31: Measuring Rotating Torque

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply MP grease around the control valve shaft as shown in the illustration.
   Fig 32: Applying MP Grease Around Control Valve Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Wrap electrical tape around the spline of the control valve.
Fig 33: Wrapping Electrical Tape Around Spline Of Control Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the dust cover to the control valve assembly.

1. Install 2 new claw washers.

   HINT:

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

2. Using SST, install the steering rack end sub-assembly (LH side).

   SST 09922-10010 

   Torque: Without SST 

   84 N*m (852 kgf*cm, 62 ft.*lbf) 

   With SST 

   60 N*m (613 kgf*cm, 44 ft.*lbf) 

   NOTE:

   • Use SST 09922-10010 as shown in the illustration.
   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   • This torque value is effective when SST is parallel to the torque wrench.

   HINT:

   Using SST, hold the steering rack and install the steering rack end sub-assembly (LH side).

   Fig 34: Installing Steering Rack End Sub-Assembly (LH Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, install the steering rack end sub-assembly (RH side).

   SST 09922-10010 

   Torque: Without SST 

   84 N*m (852 kgf*cm, 62 ft.*lbf) 

   With SST 

   60 N*m (613 kgf*cm, 44 ft.*lbf) 

   NOTE:

   • Use SST 09922-10010 as shown in the illustration.
   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   • This torque value is effective when SST is parallel to the torque wrench.

   HINT:

   Using SST, hold the steering rack end sub-assembly (LH side) and install the steering rack end sub-assembly (RH side).

   Fig 35: Installing Steering Rack End Sub-Assembly (RH Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brass bar and a hammer, stake the 2 claw washers.
   NOTE: Avoid any impact to the steering rack.
   Fig 36: Staking Claw Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Ensure that the holes of rack ends are not clogged with grease.

   HINT:

   If the holes are clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

   Fig 37: Locating Rack End Holes

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply silicon grease to the inside of the small opening of the No. 2 steering rack boot.
2. Install the No. 2 steering rack boot to the groove on the rack housing.
   NOTE:

   • Be careful not to damage or twist the No. 2 steering rack boot.
   • Do not damage the No. 2 steering rack boot.

Fig 38: Locating Steering Rack Boot

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform the same procedure as for the No. 2 steering rack boot.

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

   SST 09521-24010 Clearance: 

   2.0 mm (0.079 in.) or less 

   NOTE: Be careful not to damage the No. 2 steering rack boot.
   Fig 39: Tightening No. 2 Steering Rack Boot Clamps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers, install the 2 steering rack boot clips.
   NOTE: Make sure that the each clip claw is positioned within the area shown in the illustration.
   Fig 40: Identifying Steering Rack Boot Clip Tightening Angles

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, turn the pinion and check that the rack boots expand and contract smoothly.

   SST 09616-00011 

   Fig 41: Checking Rack Boots Expand And Contract Smoothly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the lock nut and the tie rod assembly LH to the steering rack end sub-assembly until the matchmarks are aligned.

   HINT:

   After adjusting toe-in, torque the lock nut.

Fig 42: Identifying Tie Rod Assembly Matchmarks LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform the same procedure as for the LH side.

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

   SST 09023-38201 

   Torque: Without SST 

   13 N*m (128 kgf*cm, 9 ft.*lbf) 

   With SST 

   11 N*m (114 kgf*cm, 8 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
   • This torque value is effective when SST is parallel to the torque wrench.
     Fig 43: 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 steering left turn pressure tube.
2. Using SST, install the left turn pressure tube to the power steering link assembly.

   SST 09023-38201 

   Torque: Without SST 

   13 N*m (128 kgf*cm, 9 ft.*lbf) 

   With SST 

   11 N*m (114 kgf*cm, 8 ft.*lbf) 

   NOTE:

   • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
   • This torque value is effective when SST is parallel to the torque wrench.
     Fig 44: Installing Left Turn Pressure Tube To Power Steering Link Assembly

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002