Power Steering Gear: Reassembly

1. Install SST to the rack.
   Fig 1: Installing Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09631-16020
   NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
2. Coat SST with power steering fluid.
3. Install the steering rack into the rack housing.
4. Remove the SST.
   1. SST 09631-16020

Fig 2: Installing Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
2. Coat a new oil seal lip with power steering fluid.
3. Install the oil seal by pushing it into the rack housing without tilting.
   NOTE: Make sure to install the oil seal facing in the correct direction.

1. Using SST and a hammer, drive in the cylinder end stopper.
   Fig 3: Driving In Cylinder End Stopper Using SST & A Hammer

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   1. SST 09612-2201 1
2. Using snap ring pliers, install a new snap ring to the rack housing.

Fig 4: Identifying Air Tightness Test

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1. Install 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.

Install the control valve assembly into the rack housing.

1. Coat a new bearing with molybdenum disulfide lithium base grease.
2. Using SST, press in the bearing to the rack housing.
   Fig 5: Pressing In Bearing To Rack Housing Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09612-2201 1

1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
   Fig 6: Pressing In Oil Seal Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09612-2201 1
   NOTE: Make sure to install the oil seal facing in the correct direction.
3. Using snap ring pliers, install a new snap ring to the rack housing.

1. Using SST, stop the control valve shaft rotating and install a new self-locking nut.
   Fig 7: Install Self-Locking Nut Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09616-0001 1
   2. Torque: 12 N.m (125 kgf.cm, 9 ft.lbf) 
2. Turn "C "of SST to measure the dimension "A," then set SST as shown in the illustration.
   1. SST 09613-12020
   2. Dimension A: 16.5 - 17.0 mm (0.65 - 0.67 in.) 
3. Stake the self-locking nut by turning "B" of the SST until it touches the spacer of the SST.

1. Apply sealant to 2 or 3 threads of the rack housing cap.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Install the rack housing cap.
   Fig 8: Installing Rack Housing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) 

1. Install the rack guide, conical spring and rack guide spring.
   Fig 9: Installing Rack Guide, Conical Spring, Rack Guide Spring & Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure to install the conical spring facing in the correct direction.
2. Apply sealant to 2 or 3 threads of the rack guide spring cap.
   1. Sealant: 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 a hexagon wrench (21 mm), torque the rack guide spring cap.
   Fig 10: Adjusting Total Preload Using Hexagonal Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
3. Using a hexagon wrench (21 mm), return the rack guide spring cap 12°.
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
   1. SST 09616-0001 1
5. Using a hexagon wrench (21 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
   Fig 11: Turning Control Valve Shaft Right & Left Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, a torque wrench and a hexagon wrench (21 mm), tighten the rack guide spring cap until the preload is within the specification.
   1. SST 09616-0001 1
   2. Preload (turning): 
   3. 1.1 - 1.6 N.m (11 - 16 kgf.cm, 9.7 - 14.2 in..lbf) 

1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
   1. Sealant: 
   2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Temporarily install the rack guide spring cap lock nut.
3. Using a hexagon wrench (21 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
   Fig 12: Tightening Rack Guide Spring Cap Using SST A Torque Wrench & Hexagonal Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09922-1001 1
   2. Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) 
   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   Fig 13: Holding Rack Guide Spring Cap Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Recheck the total preload.
   1. Preload (turning): 
   2. 1.1 - 1.6 N.m (11 - 16 kgf cm, 9.7 - 14.2 in. lbf) 
5. Remove the RH and LH rack ends.

1. Install a new claw washer, and temporarily install the rack end.
   NOTE: Align the claws of the claw washer with the steering rack grooves.
   Fig 14: Aligning Claws Of Claw Washer With Steering Rack Grooves

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2. Using a spanner (22 mm), hold the steering rack steadily and using SST, torque the rack end.
   Fig 15: Holding Steering Rack Steadily Using Spanner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. SST 09922-10010
   2. Torque: 60 N.m (615 kgf.cm, 44 ft.lbf) 
   NOTE: 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.).
3. Using a brass bar and a hammer, stake the washer.
   Fig 16: Staking Washer Using Brass Bar & A Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Avoid any impact on the steering rack.
4. Employ the same manner described above to the other side.

1. Install the grommet to the No. 1 rack housing bracket.
2. Align the matchmarks on the bracket and housing.
Fig 17: Aligning Matchmarks On Bracket & Housing
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3. Install and torque the bolt.
   1. Torque: 61 N.m (620 kgf.cm, 45 ft.lbf) 

1. Ensure that the steering rack hole is not clogged with grease.
   NOTE: 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 boot, clip and a new clamp.
   Fig 18: Installing Boot, Clip & A New Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage or twist the boot.
3. Tighten the clamp as shown in the illustration.
Fig 19: Tightening Clamp
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4. Employ the same manner described above to the other side.

1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
2. Employ the same manner described above to the other side.
3. After adjusting toe-in, torque the nut (See INSPECTION )
   1. Torque: 74 N.m (750 kgf.cm, 54 ft.lbf) 
   Fig 20: Aligning Matchmarks On Tie Rod

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Using SST, install the 2 turn pressure tubes.

Fig 21: Installing Turn Pressure Tubes Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. SST 09023-38200
2. Torque: 27 N.m (270 kgf.cm, 20 ft.lbf)