Steering Linkage: Reassembly

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.
   NOTE:

   • Ensure 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.
   Fig 1: 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.
   NOTE: Do not turn the SST when inserting the oil seal.
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 2: Installing Power Steering Cylinder Tube Oil Seal

   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 the new oil seal with your fingers.
   NOTE: Be careful not to overly expand the oil seal.
3. Coat the oil seal with power steering fluid.
   Fig 3: Expanding Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the oil seal to the steering rack, and adjust with your fingers.
   Fig 4: Adjusting Oil Seal

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5. Apply molybdenum disulfide lithium base grease to the rack teeth ends.

   HINT:

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

6. Affix SST to the steering rack.

   SST 09631-20102 

   Coat SST with power steering fluid.

7. Install the steering rack to the rack housing.
8. Remove SST.

Fig 5: Fixing SST To Steering Rack

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1. Wrap vinyl tape around the RH side of the power steering rack and apply power steering fluid.
2. Apply power steering fluid to the lip of a new cylinder end stopper oil seal.
3. Install the cylinder end stopper oil seal to the RH side of the rack housing.
   NOTE:

   • Ensure that the cylinder end stopper oil seal is installed in the correct direction as shown in the illustration.
   • Do not damage the cylinder end stopper oil seal.
4. Remove the vinyl tape from the power steering rack.
5. Apply power steering fluid to a new cylinder end stopper O-ring.
6. Install the cylinder end stopper O-ring to the cylinder end stopper.
   Fig 6: Applying Power Steering Fluid To Cylinder End Stopper O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install a new cylinder end stopper bush to the cylinder end stopper.
8. Apply molybdenum disulfide lithium base grease to the entire inner side of the cylinder end stopper bush.
   Fig 7: Applying Molybdenum Disulfide Lithium Base Grease To Inner Side Of Cylinder End Stopper Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Using SST, install the cylinder end stopper to the rack housing.

   SST 09631-20120 

   Torque: 122 N*m (1,244 kgf*cm, 90 ft.*lbf) 

   Fig 8: Installing Cylinder End Stopper To Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   SST 09631-12071 (09633-00010) 

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.

   Fig 9: Testing Air Tightness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09950-70010 (09951-07150), 09950-60010 (09952-06010, 09951-00180, 09951-00300) 

   NOTE: Make sure that the oil seal is installed in the correct direction as shown in the illustration.
   Fig 10: Installing Control Valve Upper Oil Seal

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

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

Fig 11: Installing Control Valve Upper Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Expand 4 new valve spacers with your fingers.
   NOTE: Be careful not to overly expand the valve spacers.
2. Coat the 4 valve spacers with power steering fluid.
   Fig 12: Expanding Valve Spacers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 4 valve spacers to the control valve, and adjust with your fingers.
   Fig 13: Adjusting Valve Spacers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat the control valve with power steering fluid.
5. Install the control valve into the valve housing.
   NOTE: Be careful not to damage the valve spacers and oil seal lip.

   HINT:

   Wrap vinyl tape around the end of the steering rack in order to prevent damaging the oil seal.

   Fig 14: Installing Control Valve Into Valve Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the control valve housing with the control valve and a new gasket to the rack housing with the 2 bolts.

   Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

   Fig 15: Installing Control Valve Housing With Control Valve And Gasket To Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide and the power steering rack.
2. Install the rack guide and the compression spring.
3. 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 

4. Using a 24 mm straight hexagon wrench, temporarily install the rack guide spring cap.

Fig 16: Installing Rack Guide

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 24 mm straight hexagon wrench, loosen and retighten the rack guide spring cap.
2. Temporarily install the steering rack ends to the power steering rack.
   NOTE: Do not fully turn the power steering rack without the steering rack end as it may damage the oil seal in the rack housing and the cylinder end stopper bush.
   Fig 17: Inspecting Total Preload (1 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, fully turn the power steering rack right and left 10 times to settle.

   SST 09616-00011 

4. While turning the control valve using SST, loosen the rack guide spring cap in small amounts until the preload falls within the specified range.

   SST 09616-00011 

   Standard preload (turning): 0.9 to 1.6 N*m (9.2 to 16.3 kgf*cm, 8.0 to 14.2 in.*lbf) 

   NOTE: Retighten and loosen the rack guide spring cap if preload falls below the specified range.
5. Remove the steering rack ends from the power steering rack.

Fig 18: Inspecting Total Preload (2 Of 2)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new claw washers, and temporarily install the rack ends.

   HINT:

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

2. Apply MP grease to the rack end ball joint.
3. Using 2 SST, install the rack end sub-assembly (LH side).

   SST 09922-10010 

   Torque: 73 N*m (744 kgf*cm, 54 ft.*lbf) 

   HINT:

   • 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.).
   • Using SST, hold the rack and install the rack end sub-assembly.
   Fig 19: Installing Rack End Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and a 22 mm wrench, tighten the rack end sub-assembly (RH side).

   SST 09922-10010 

   Torque: 73 N*m (744 kgf*cm, 54 ft.*lbf) 

   HINT:

   • 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.).
   • Using SST, hold the rack and install the rack end sub-assembly.
5. Using a brass bar and hammer, stake the 2 claw washers.
   NOTE: Avoid any impact to the steering rack.
   Fig 20: Staking Claw Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. 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.

Fig 21: Locating Steering Rack Hole

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1. Apply silicon grease to the inside of the small opening of the No. 2 rack boot.
   Fig 22: Locating Small Opening Of No. 2 Rack Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install a new steering rack boot clamp to the large opening of the steering rack boot at the position shown by arrow (A).
   NOTE:

   • Use a new steering rack boot clamp.
   • Do not expand the steering rack boot clamp more than necessary to perform installation.
   • Do not deform the steering rack boot clamp.
   • Tightening force of the steering rack boot clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the boot and rack housing, causing a malfunction.
   • Use only the supply parts which are applicable to the vehicle to secure the boot.
   Fig 23: Identifying Correct Installation Of Steering Rack Boot Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   After disengaging the claw of a new steering rack boot clamp, temporarily install it from the end without expanding the clamp diameter as much as possible.

3. Install the rack boot to the groove on the rack housing.
   NOTE:

   • Be careful not to damage or twist the boot.
   • Do not damage the steering rack boot.
   • Ensure that the steering rack boot clamp is installed before installing the steering rack boot to the rack housing.

HINT:

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

1. Using pliers and a screwdriver, install a new rack boot clamp.

Fig 24: Installing No. 2 Steering Rack Boot Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform the same procedure as for the clamp.

1. Using pliers, install the 2 boot clips.
2. Using SST, turn the control valve, and check that the rack boots expand and contract smoothly.

   SST 09616-00011 

   Fig 25: Installing Steering Rack Boot Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Screw the lock nut and the tie rod end to the rack end until the matchmarks are aligned.

   HINT:

   After adjusting toe-in, torque the lock nut.

   Fig 26: Aligning Tie Rod End And Rack End Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Perform the same procedure as for the LH.