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Power Steering Gear: Reassembly

NOTE: 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  COMPONENTS  ) 
  2. INSTALL OIL SEAL 
    1. Coat a new oil seal lip with power steering fluid.
      2. CAUTION:
      • 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
      G02901630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal.
      1. SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)
  3. INSTALL STEERING RACK 
      NOTE:

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

      Fig 2: Installing Steering Rack
      G02901631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST to the rack.
      1. SST 09631-20051
    2. Coat the SST with power steering fluid.
      3. CAUTION: Be careful not to damage the oil seal lip.
    3. Install the steering rack into the rack housing.
    4. Remove the SST.
      1. SST 09631-20051
  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: Wrapping Vinyl Tape On Steering Rack End, And Applying Power Steering Fluid
      G02901632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. CAUTION:
      • Make sure to install the bushing facing in the correct direction.
      • Be careful not to damage the oil seal lip.
    3. Install the bushing.
  5. INSTALL CYLINDER END STOPPER 
    1. Align the installation hole for the wire of the stopper with the slot of the rack housing.
      Fig 4: Installing Cylinder End Stopper Wire
      G02901633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new wire into the stopper.
    3. Using SST, turn the stopper clockwise 450 +/- 50°.
      1. SST 09631-16010
  6. AIR TIGHTNESS TEST 
    1. Install SST to the rack housing.
      Fig 5: Identifying Air Tightness Test
      G02901634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 change in the vacuum, check the installation of the oil seals.

  7. INSTALL CONTROL VALVE ASSEMBLY 
    1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
      Fig 6: Installing Control Valve Assembly
      G02901635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the teflon rings with power steering fluid.
      3. CAUTION: Be careful not to damage the teflon rings and oil seal.
    3. Install the valve assembly into the valve housing.
  8. INSTALL OIL SEAL 
    1. Coat a new oil seal lip with power steering fluid.
      Fig 7: Installing Oil Seal
      G02901636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. CAUTION: Make sure to install the oil seal facing in the correct direction.
    2. Using SST, press in the oil seal.
      1. SST 09612-2201 1
  9. 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 with control valve assembly and rack housing.
    3. Install the 2 bolts.
      1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
  10. INSTALL SELF-LOCKING NUT 

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

    Fig 8: Installing Self-Locking Nut
    G02901637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. SST 09616-0001 1
    2. Torque: 30 N.m (300 kgf.cm, 22 ft.lbf) 
  11. INSTALL DUST COVER 
  12. INSTALL RACK HOUSING CAP 
    1. Apply sealant to 2 or 3 threads of the rack housing cap.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Using SST, install the rack housing cap.
      Fig 9: Installing Rack Housing Cap
      G02901638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09816-30010
      2. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) 
    3. Using a punch and hammer, stake the 2 parts of the cap.
      Fig 10: Staking Cap
      G02901639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP 
    1. Install the rack guide and rack guide spring.
    2. Apply sealant to 2 or 3 threads of the rack guide spring cap.
      1. Sealant: 
      2. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Temporarily install the rack guide spring cap.
  14. 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 a hexagon wrench, install the rack guide spring cap.
      1. 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 Total Preload
      G02901640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.
      Fig 12: Turning Control Valve Shaft Right And Left
      G02901641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09616-0001 1
    5. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning.
    6. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload is within specification.
      Fig 13: Tightening Rack Guide Spring Cap
      G02901642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09616-0001 1
      2. Preload (turning): 
      3. 1.0 - 1.45 N.m (10 - 14.5 kgf.cm, 8.7 - 12.6 in..lbf) 
  15. INSTALL RACK GUIDE SPRING CAP LOCK NUT 
    1. Apply sealant to 2 or 3 threads of the lock nut.
      1. Sealant: 
        1. Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    2. Temporarily install the lock nut.
      3. CAUTION: Use SST 09922-10010 in the direction shown in Fig 14.
      Fig 14: Installing Rack Guide Spring Cap Lock Nut
      G02901643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
    3. Using a hexagon wrench to hold the rack guide spring cap, and using SST, torque the lock nut.
      1. SST 09922-10010
      2. Torque: 51 N.m (520 kgf.cm, 38 ft.lbf) 
    4. Recheck the total preload.
      1. Preload (turning): 
      2. 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.
  16. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS 
      NOTE:

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

      Fig 15: Installing RH And LH Claw Washers And Rack Ends
      G02901644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new claw washer, and temporarily install the rack end.
      2. 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: Holding Steering Rack Steady And Torque Rack End
      G02901645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
      1. SST 09922-10010
      2. Torque: 76 N.m (770 kgf.cm, 56 ft.lbf) 
      3. CAUTION: Avoid any impact on the rack.
      Fig 17: Using A Brass Bar And Hammer, Staking Washer
      G02901646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and hammer, stake the washer.
    4. Employ the same manner described above to the other side.
  17. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS 
      NOTE:

      If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

    1. Ensure that the steering rack hole is not clogged with grease.
    2. Set a new clamp to the groove of the rack boot.
      Fig 18: Ensuring Steering Rack Hole Is Not Clogged With Grease
      G02901647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. CAUTION: Be careful not to damage or twist the boot.
    3. Install the boot.
    4. Using SST, tighten the clamp as shown in Fig 19.
      Fig 19: Tightening Clamp
      G02901648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. SST 09521-24010
    5. Install the clip to the rack boot.
    6. Employ the same manner described above to the other side.
  18. 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.
    2. After adjusting toe-in, torque the nut (See INSPECTION ).
      1. Torque: 55 N.m (560 kgf.cm, 41 ft.lbf) 
  19. INSTALL 2 TURN PRESSURE TUBES 
    1. Coat 4 new O-rings with power steering fluid and install them to the turn pressure tubes.
      Fig 20: Installing Turn Pressure Tubes
      G02901649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Using SST, install the 2 turn pressure tubes.
      1. SST 09023-12700
      2. Torque: 12 N.m (117 kgf.cm, 9 ft.lbf) 
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