Power Steering Gear: Reassembly

NOTE: When using a vise, do not overtighten it.

COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
(See COMPONENTS ).
INSTALL STEERING RACK
1. Install SST to the rack.
  SST 09631-00350
  
  Fig 1: Installing SST To Steering Rack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If necessary, scrape the burrs off the rack teeth end and burnish.
2. Coat SST with power steering fluid.
3. Install the rack into the rack housing.
4. Remove the SST.
INSTALL OIL SEAL
1. Install SST to the steering rack opposite end.
  SST 09631-00350
2. Coat SST with power steering fluid.
3. Coat a new oil seal lip with power steering fluid.
4. Install the oil seal by pushing it onto the SST without tilting.
  
  Fig 2: Installing SST To Steering Rack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure to install the oil seal facing the correct direction.
5. Remove the SST.
INSTALL SPACER AND CYLINDER END STOPPER
1. Install the spacer.
2. Coat a new O-ring with power steering fluid, and install it to the stopper.
3. Using a wooden block and hammer, drive in the stopper until it is tightly installed.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 3: Installing Spacer And Cylinder End Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, torque the stopper.
SST 09922-10010

Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf)

Fig 4: Identifying fulcrum length(380 mm)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

Use a torque wrench with a fulcrum length of 380 mm (14.97 in.).
AIR TIGHTNESS TEST
1. Install SST to the unions of the rack housing.
  SST 09631-12071
2. Apply 53 kPa (400 mm Hg, 15.75 in. Hg) of vacuum for about 30 seconds.
3. Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.
INSTALL CONTROL VALVE ASSEMBLY
1. Coat the teflon rings with power steering fluid.
2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
3. Push the valve assembly into the control valve housing.
  NOTE: Be careful not to damage the teflon rings and oil seal lip.
  
  Fig 6: Installing Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
5. Using SST, torque the nut.
  SST 09631-20060
  
  Fig 7: Installing Bearing Guide Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
  
  NOTE: Be careful not to damage the oil seal lip.
6. Using a punch, stake the nut.
  
  Fig 8: Staking With Punch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Coat a new O-ring with power steering fluid, and install it to the valve housing.
2. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing.
3. Torque the 2 bolts.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
INSTALL DUST COVER
INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
1. Apply sealant to 2 or 3 threads of the cap.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344,
  
  LOCTITE 242 or equivalent
2. Temporarily install the cap.
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. Torque the rack guide spring cap.
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
3. Return the cap 19°.
  
  Fig 9: Adjusting Total Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
  SST 09616-0001 1
  
  Fig 10: Turning Control Valve Shaft Right And Left
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Loosen the cap until the rack guide spring is not functioning.
6. Using SST and a torque wrench, tighten the cap until the preload is within specification.
  SST 09616-0001 1
  
  Fig 11: Tightening Cap Until Specified Preload
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Preload (turning):
  
  Center Area
  
  1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf)
  
  End Area
  
  1.3 - 1.7 N.m (13.3 - 17.3 kgf.cm, 11.5 - 15.0 in.lbf)
INSTALL RACK GUIDE SPRING CAP LOCK NUT
1. Apply sealant to 2 or 3 threads of the nut.
  Sealant:
  
  Part No.08833-00080, THREE BOND 1344,
  
  LOCTITE 242 or equivalent
2. Holding the rack guide spring cap rotating, and using SST, torque the nut.
  SST 09922-10010
  
  Fig 12: Installing Rack Guide Spring Cap Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 52 N.m (520 kgf.cm, 38 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 (14.97 in.).
3. Recheck the total preload.
  Preload (turning):
  
  Center Area
  
  1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf)
  
  End Area
  
  1.3 - 1.7 N.m (13.3 - 17.3 kgf.cm, 11.5 - 15.0 in.lbf)
4. Remove the RH and LH rack ends.
INSTALL RH AND LH CLAW WASHERS AND RACK ENDS
1. Install a new washer, and temporarily tighten the rack end.
  HINT:
  
  Fig 13: Identifying Rack Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Align the claws of the washer with the steering rack grooves.
2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
  SST 09922-10010
  
  Fig 14: Identifying Fulcrum Length (380 mm)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 99 N.m (1,014 kgf.cm, 74 ft.lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 380 mm (13.58 in.).
3. Using a brass bar and hammer, stake the washer.
  NOTE: Avoid any impact to the rack.
  
  Fig 15: Staking Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Employ the same manner described to the other side.
INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
1. Ensure that the tube hole is not clogged with grease.
  
  Fig 16: Locating Tube Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
2. Install the boot.
  NOTE: Be careful not to damage or twist the boot.
3. Using pliers tighten a new clamp, as shown in the illustration.
4. Employ the same manner described to the other side.
INSTALL 2 TURN PRESSURE TUBES
Using SST, install the tube.

SST 09023-38200

Fig 18: Identifying Fulcrum Length (300 mm)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 23 N.m (230 kgf.cm, 17 ft.lbf)

HINT:
- 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.