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.
  1. SST 09631-00350
  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.
Fig 1: Installing SST To Steering Rack
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL SEAL

Fig 2: Installing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install SST to the steering rack opposite end.
  1. 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.
  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 Cylinder End Stopper & Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, torque the stopper.
1. SST 09922-10010
2. Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf)
NOTE: Use SST 09922-10010 in the direction shown in Fig 4 .

Fig 4: Torquing Stopper With Torque Wrench Of Fulcrum Length Of 380 MM
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Use a torque wrench with a fulcrum length of 380 mm (14.97 in.).

Fig 5: Installing SST To Rack Housing Unions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
AIR TIGHTNESS TEST
1. Install SST to the unions of 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 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: Windings Vinyl Tape On Control Valve Shaft Serrated Part
  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.
  1. SST 09631-20060
  2. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) NOTICE: Be careful not to damage the oil seal lip.
  Fig 7: Torquing Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a punch, stake the nut.
Fig 8: Stacking Nut Using 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.
1. 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:
  1. 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.
  1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
3. Return the cap 19°.
  
  Fig 9: Returning Cap 19°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
  1. SST 09616-0001 1
5. Loosen the cap until the rack guide spring is not functioning.
  
  Fig 10: Turning Control Valve Shaft Right & Left 1 Or 2 Times
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a torque wrench, tighten the cap until the preload is within specification.
1. SST 09616-0001 1
2. Preload (turning):
3. Center Area
4. 1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf)
5. End Area
6. 1.3 - 1.7 N.m (13.3 - 17.3 kgf.cm, 11.5 - 15.0 in.lbf)
Fig 11: Tightening Cap Within Its Specified Preload
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RACK GUIDE SPRING CAP LOCK NUT
1. Apply sealant to 2 or 3 threads of the nut. Sealant:
  1. 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.
  1. SST 09922-10010
  2. Torque: 52 N.m (520 kgf.cm, 38 ft.lbf)
  NOTE: Use SST 09922-10010 in the direction shown in Fig 12 .
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 345 mm (14.97 in.).
3. Recheck the total preload.
  1. Preload (turning):
  2. Center Area
  3. 1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf)
  4. End Area
  5. 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:
  
  Align the claws of the washer with the steering rack grooves.
  
  Fig 13: Locating Rack Groove
  Courtesy 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: 99 N.m (1,014 kgf.cm, 74 ft.lbf)
  NOTE: Use SST 09922-10010 in the direction shown in Fig 14 .
  
  Fig 14: Torquing Rack End Using Torque Wrench Of Fulcrum Length 380 MM
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
4. Employ the same manner described above to the other side.
  
  Fig 15: Stacking Washer Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
1. Ensure that the tube hole is not clogged with grease.
  HINT:
  
  If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
  
  Fig 16: Locating Tube Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the boot.
  NOTE: Be careful not to damage or twist the boot.
3. Using pliers tighten a new clamp, as shown in Fig 17 .
4. Employ the same manner described above to the other side.
Fig 17: Tightening New Clamp Using Pliers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2 TURN PRESSURE TUBES
Using SST, install the tube.
1. SST 09023-38200
2. 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.
Fig 18: Installing 2 Turns Pressure Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002