Power Steering Gear: Reassembly

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

   SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)

   NOTE:

   • Make sure to install the oil seal facing in the correct direction.
   • Take care that the oil seal does not get reversed as you install it.
     Fig 1: Installing Oil Seal

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack.

   SST 09631-20051

   HINT: If necessary, scrape the burrs off the rack teeth end and burnish.

2. Coat the SST with power steering fluid.
3. Install the steering rack into the rack housing.
   NOTE: Be careful not to damage the oil seal lip.
4. Remove the SST.

   SST 09631-20051

   Fig 2: Installing Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
3. Install the bushing.
   NOTE:

   • Make sure to install the bushing facing in the correct direction.
   • Be careful not to damage the oil seal lip.
     Fig 3: Installing Bushing

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the installation hole for the wire of the stopper with the slot of the rack housing.
2. Install a new wire into the stopper.
3. Using SST, turn the stopper clockwise 450 +/- 50°.

   SST 09631-16010

   Fig 4: Installing Cylinder End Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   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 change in the vacuum, check the installation of the oil seals.

   Fig 5: Checking Air Tightness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
2. Coat the teflon rings with power steering fluid.
3. Install the valve assembly into the valve housing.
   NOTE: Be careful not to damage the teflon rings and oil seal.
   Fig 6: Installing Control Valve Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09612-2201 1

   NOTE: Make sure to install the oil seal facing in the correct direction.
   Fig 7: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new gasket on the rack housing.
2. Align the matchmarks on the control valve housing with control valve assembly and rack housing.
3. Install the 2 bolts.

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

Using SST to stop the control valve shaft rotating, install a new nut.

SST 09616-0001 1

Torque: 30 N.m (300 kgf.cm, 22 ft.lbf) 

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. Using SST, install the rack housing cap.

   SST 09816-30010

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

   Fig 9: Installing Rack Housing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a punch and hammer, stake the 2 parts of the cap.

1. Install the rack guide 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.
   Fig 10: Installing Rack Guide, Spring & Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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, install the rack guide spring cap.

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

3. Using a hexagon wrench, return the rack guide spring cap 12°.
   Fig 11: Adjusting Rack Guide Spring Cap

   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

5. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning.
   Fig 12: Turning Control Valve Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload is within specification.

   SST 09616-0001 1

   Preload (turning): 1.0 - 1.45 N.m (10 - 14.5 kgf.cm, 8.7 - 12.6 in.lbf) 

   Fig 13: Tightening Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply sealant to 2 or 3 threads of the lock nut.

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

2. Temporarily install the lock nut.
3. Using a hexagon wrench to hold the rack guide spring cap, and using SST, torque the lock nut.

   SST 09922-10010

   Torque: 51 N.m (520 kgf.cm, 38 ft.lbf) 

   Fig 14: Installing Rack Guide Spring Cap Lock Nut

   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 345 mm (13.58 in.).

4. Recheck the total preload.

   Preload (turning): 1.0 - 1.45 N.m (10 - 14.5 kgf.cm, 8.7 - 12.6 in.lbf) 

5. Remove the RH and LH rack ends.

1. Install a new claw washer, and temporarily install the rack end.

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

   Fig 15: Installing RH & LH Claw Washer & Rack Ends

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.

   SST 09922-10010

   Torque: 76 N.m (770 kgf.cm, 56 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 (13.58 in.).

   Fig 16: Tightening Rack End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, stake the washer.
   NOTE: Avoid any impact on the rack.
4. Employ the same manner described above to the other side.
   Fig 17: Using Brass Bar & Hammer To Stake Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. 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.

2. Set a new clamp to the groove of the rack boot.
   Fig 18: Installing RH & LH Rack Boots Clamps & Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the boot.
   NOTE: Be careful not to damage or twist the boot.
4. Using SST, tighten the clamp as shown in the illustration.

   SST 09521-24010

5. Install the clip to the rack boot.
6. Employ the same manner describer above to the other side.
   Fig 19: Installing Clip To Rack Boot

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
2. After adjusting toe-in, torque the nut (See INSPECTION ).

   Torque: 55 N.m (560 kgf.cm, 41 ft.lbf) 

1. Coat 4 new O-rings with power steering fluid and install them to the turn pressure tubes.
2. Using SST, install the 2 turn pressure tubes.

   SST 09023-12700

   Torque: 12 N.m (117 kgf.cm, 9 ft.lbf) 

   HINT:

   • 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 20: Installing 2 Turn Pressure Tubes

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002