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Power Steering Gear: Reassembly

WARNING: This page is about a different car, the 2002 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.
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 COMPONENTS .
  2. Install oil seal:
    1. Coat a new oil seal lip with power steering fluid.
      2. NOTE:
      • 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.
      Fig 1: Pressing Oil Seal Into Steering Rack
      G01102439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal.

      SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

  3. Install steering rack:
      NOTE: If necessary, scrape the burrs off the steering rack teeth end and burnish.
    1. Install SST to the steering rack. SST 09631-33010.
    2. Coat the SST with power steering fluid.
      3. CAUTION: Be careful not to damage the oil seal lip.
      Fig 2: Using SST To Install Steering Rack Into Housing
      G01102440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the steering rack into the rack housing.
    4. Remove SST. SST 09631-33010.
    4. NOTE:
    • Make sure that the bushing is installed facing in the correct direction.
    • Be careful not to damage the oil seal lip.
  4. Install bushing:
    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.
      Fig 3: Using Vinyl Tape To Prevent Oil Seal Damage
      G01102441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bushing.
  5. Install cylinder end stopper:
    1. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
      Fig 4: Installing Cylinder End Stopper & Wire
      G01102442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new wire into the cylinder end stopper.
    3. Using SST, turn the cylinder end stopper clockwise 450 +/- 50°. SST 09631-10021.
  6. Air tightness test:
    1. Install SST to the rack housing. SST 09631-12071.
      Fig 5: Using Vacuum To Check For Internal Leaks
      G01102443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  7. Install rack housing No. 2 bracket and rack hosing No. 2 grommet:
      NOTE: Align the projection of the rack housing No. 2 grommet with the hole of the rack housing No. 2 bracket.
      Fig 6: Aligning Grommet Hole & Rack Housing No. 2 Bracket Hole
      G01102444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the rack housing No. 2 grommet to the rack housing No. 2 bracket.
    2. Align the matchmarks on the rack housing No. 2 bracket and rack housing.
    3. Place the rack housing No. 2 bracket in a vise and install the vise to fasten the clamp.
      Fig 7: Using Vise To Reconnect Clamp Ends
      G01102445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install control valve assembly:
    1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
    2. Coat the teflon rings with power steering fluid.
      3. CAUTION: Be careful not to damage the teflon rings and oil seal.
      Fig 8: Using Vinyl Tape To Prevent Damage During Control Valve Assembly Installation
      G01102446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the control valve assembly into the control valve housing.
  9. Install oil seal:
    1. Coat a new oil seal lip with power steering fluid.
      2. NOTE: Make sure that the oil seal is installed facing in the correct direction.
      Fig 9: Installing Control Valve Assembly Oil Seal
      G01102447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST press in the oil seal. SST 09612-22011.
  10. Install control valve housing with control valve assembly:
    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.

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

  11. Using SST, stop the control valve shaft rotating and install a new self-locking nut. SST 09616-00011.
    Fig 10: Installing Self-Locking Nut
    G01102448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  12. Install dust seal.
  13. Install rack housing cap:
    1. Apply sealant to 2 or 3 threads of the rack housing cap.

      Sealant:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.

    2. Install the rack housing cap.

      Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) 

    3. Using a punch and hammer, stake the 2 parts of the rack housing cap.
      Fig 11: Staking Rack Housing Cap
      G01102449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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.

      Sealant:  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.

    3. Temporarily install the rack guide spring cap.
  15. 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 SST, torque the rack guide spring cap. SST 09631-10021.
      Fig 12: Tightening Rack Guide Spring Cap
      G01102450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Using SST, return the rack guide spring cap 12°. SST 09631-10021.
      Fig 13: Using SST To Turn Rack Guide Spring Cap
      G01102451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011.
      Fig 14: Using SST To Turn Control Valve Shaft
      G01102452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning. SST 09631-10021.
    6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.

      SST 09616-00011, 09631-10021

      Fig 15: Setting Preload On Rack Guide Spring Cap
      G01102453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (turning):  0.8 - 1.4 N.m (8-14 kgf.cm, 6.9 - 12.2 in. lbf).

  16. Install rack guide spring cap lock nut  :
    1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.

      Sealant:  Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent.

    2. Temporarily install the rack guide spring cap lock nut.
      3. NOTE: Use SST 09922-10010 in the direction shown in Fig 16.

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

      Fig 16: Tightening Rack Guide Spring Cap Lock Nut
      G01102454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, hold the rack guide spring cap and using another SST torque the rack guide spring cap lock nut. SST 09631-10021, 09922-10010.

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

    4. Recheck the total preload.

      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.
  17. Install RH and LH claw washers and rack ends:
      NOTE: Align the claws of the claw washers with the steering rack grooves.
      Fig 17: Installing Claw Washer
      G01102455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new claw washer, and temporarily install the rack ends.
      2. NOTE: Use SST 09922-10010 in the direction shown in Fig 18.

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

      Fig 18: Tightening Rack End
      G01102456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end. SST 09922-10010.

      Torque: 60 N.m (610 kgf.cm, 44 ft.lbf) 

      3. CAUTION: Avoid any impact on the steering rack.
      Fig 19: Staking Claw Washer
      G01102457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and hammer, stake the claw washer.
    4. Employ the same manner described above to the other side.
  18. Install RH and LH rack boots, clamps and clips  :
      CAUTION: If the hole is clogged, the pressure inside the rack boot will change after it is assembled and the steering wheel is turned.
      Fig 20: Locating Steering Rack Hole
      G01102458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Ensure that the steering rack hole is not clogged with grease.
      2. CAUTION: Be careful not to damage or twist the rack boot.
    2. Install the rack boot, clip and a new clamp.
    3. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010.
      Fig 21: Using SST To Tighten Clamp
      G01102459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Employ the same manner described above to the other side.
  19. 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 22: Aligning Match Marks On Tie Rod End
      G01102460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. After adjusting toe-in, torque the lock nut. See SPECIFICATIONS & PROCEDURES .

      Torque: 74 N.m (750 kgf.cm, 54 ft.lbf)  .

    3. Employ the same manner described above to the other side.
  20. Install 2 turn pressure tubes  :
    1. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
      2. NOTE:
      • 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 23: Using SST To Install Turn Pressure Tubes
      G01102461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the 2 turn pressure tubes. SST 09023-38200.

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

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