Power Steering Link: Reassembly

1. Coat a new O-ring with power steering fluid and install it to the steering rack.
2. Expand the new oil seal with your fingers.
   NOTE: Be careful not to overly expand the oil seal.
   Fig 1: Identifying New Power Piston Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat the oil seal with power steering fluid.
4. Install the oil seal to the steering rack, and adjust with your fingers.
   Fig 2: Identifying Power Steering Cylinder Tube Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360) 

   Fig 3: Using SST & Press To Install Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the oil seal is installed correctly.

1. Apply grease to the rack teeth ends.
   Fig 4: Applying Grease To Rack Teeth Ends

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Affix SST to the steering rack.

   SST 09631-33010 

   HINT:

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

3. Coat SST with power steering fluid.
4. Install the steering rack to the rack housing.
5. Remove SST.

1. Coat a new rack bush oil seal lip with power steering fluid.
2. Using SST and a press, install the rack bush oil seal to the rack bush.

   SST 09950-60010 (09951-00400), 09950-70010 (09951-07100) 

   Fig 5: Using SST & Press To Install Rack Bush Oil Seal To Rack Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the oil seal is installed correctly.
3. Coat a new O-ring with power steering fluid and install it to the rack bush.
4. Coat rack bush oil seal lip with power steering fluid.
5. Install the rack bush to the rack housing.

   HINT:

   Wrap vinyl tape around the end of the steering rack in order to prevent damaging the rack bush oil seal.

   Fig 6: Wrapping Vinyl Tape Around End Of Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
2. Install a new wire into the cylinder end stopper.
3. Using a screwdriver, turn the cylinder end stopper counterclockwise by 450° +- 50°.
   Fig 7: Using Screwdriver To Turn Cylinder End Stopper Counterclockwise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   SST 09631-12071(09633-00010) 

2. Apply a vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds.
   Fig 8: Testing Air Tightness

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.

1. Coat the control valve upper bearing with grease, and a new control valve upper oil seal lip with power steering fluid.
2. Using SST and a press, install a new control valve upper oil seal.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00320) 

   Fig 9: Using SST & Press To Install New Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the oil seal is installed correctly.
3. Using SST and a press, install the control valve upper bearing.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340) 

   Fig 10: Using SST & Press To Install Control Valve Upper Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Expand 4 new valve spacers with your fingers.
   Fig 11: Expanding New Valve Spacers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to overly expand the valve spacers.
2. Coat the 4 valve spacers with power steering fluid.
3. Install the 4 valve spacers to the control valve, and adjust with your fingers.
   Fig 12: Identifying Control Valve Spacers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Carefully slide the tapered end of SST over the valve spacers until they fit to the control valve.

   SST 09631-20081 

   NOTE: Be careful not to damage the valve spacers.
5. Coat the oil seal lip with power steering fluid.
6. Install the control valve into the valve housing.
   NOTE: Be careful not to damage the valve spacer and oil seal lip.

   HINT:

   Wrap vinyl tape around the end of the steering rack in order to prevent damaging the oil seal.

   Fig 13: Wrapping Vinyl Tape Around End Of Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Coat a new oil seal lip with power steering fluid.
8. Using SST and a press, install the oil seal.

   SST 09612-22011 

   Fig 14: Using SST & Press To Install Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the oil sea! is installed correctly.
9. Apply grease to the needle roller bearing of the rack housing and the serrated part of the control valve.
10. Install a new gasket to the valve housing.
11. Install the control valve housing with control valve to the rack housing with the 2 bolts.

    Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    Fig 15: Identifying Control Valve Housing Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Wrap vinyl tape around the lower spline of the control valve in order to prevent damaging the oil seal.

12. Using SST, keep the control valve from rotating and install a new lock nut.

    SST 09616-00011 

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

    Fig 16: Using SST To Keep Control Valve From Rotating & Install New Lock Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Apply sealant to 2 or 3 threads of the rack housing cap.

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

14. Using a socket wrench (27 mm), install the rack housing cap.

    Torque: 59 N*m (597 kgf*cm, 43 ft.*lbf) 

    Fig 17: Using Socket Wrench To Install Rack Housing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Using a punch and a hammer, stake the rack housing cap and the rack housing.
    Fig 18: Staking Rack Housing Cap & Rack Housing Using Punch & Hammer

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply grease to the compression spring and the contact surface of the rack guide.
2. Install the rack guide and the compression spring.
3. Apply sealant to 2 or 3 threads of the rack guide spring cap.

   Sealant: TOYOTA Genuine Adhesive 1344, THREE BOND 1344 or equivalent 

4. Temporarily install the rack guide spring cap.

1. temporarily install the RH and LH rack ends sub-assembly, in order to prevent the oil seal damaging by the rack teeth.
2. Using SST, torque the rack guide spring cap.

   SST 09631-10021 

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

   Fig 19: Tightening Rack Guide Spring Cap Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, loosen the rack guide spring cap.

   SST 09631-10021 

   Fig 20: Loosening Rack Guide Spring Cap Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve to right and left 1 or 2 times.

   SST 09616-00011 

   Fig 21: Turning Control Valve To Right & Left Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, loosen the rack guide spring cap until the compression spring stop functioning.

   SST 09631-10021 

6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload falls within specifications.

   SST 09616-00011, 09631-10021 

   Torque: Preload (turning) 1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6 to 13.3 in.*lbf) 

   Fig 22: Tightening Rack Guide Spring Cap Using SST & Torque Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.

   Sealant: TOYOTA Genuine Adhesive 1344, THREE BOND 1344 or equivalent 

8. Temporally install the rack guide spring cap lock nut.
9. Using SST, hold the rack guide spring cap and using another SST, torque the spring cap lock nut.

   SST 09616-00011, 09922-10010 

   Torque: 51 N*m (515 kgf*cm, 38 ft.*lbf) 

   Fig 23: Tightening Rack Guide Spring Cap Nut Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Use SST 09922-10010 following the direction shown above.

   HINT:

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

10. Precheck the total preload.

    Torque: Preload (turning) 1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6 to 13.3 in.*lbf) 

11. Remove the RH and LH rack ends sub-assembly.
12. Apply MP grease around the control valve shaft.
    Fig 24: Applying MP Grease Around Control Valve Shaft

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Wrap vinyl tape around the spline of the control valve.
    Fig 25: Wrapping Vinyl Tape Around Spline Of Control Valve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Install the dust cover to the control valve housing.

1. Install 2 new claw washers, and temporarily install the rack ends sub-assembly.

   HINT:

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

2. Using SST, install the 2 rack end sub-assembly.

   SST 09922-10010 

   Torque: 50 N*m (505 kgf*cm, 37 ft/lbf) 

   NOTE: Use SST 09922-10010 following the direction shown below.

   HINT:

   • Using SST, hold the rack and install the rack end sub-assembly.
   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
     Fig 26: Identifying Torque Wrench With Fulcrum Length

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and a hammer, stake the 2 claw washers.
   NOTE: Avoid any impact to the steering rack.
   Fig 27: Staking Claw Washers Using Brass Bar & Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Ensure that the holes of rack ends are not clogged with grease.

   HINT:

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

   Fig 28: Identifying Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, tighten the rack boot No. 2 clamp.

   SST 09521-24010 

   Clearance: 3.0 mm (0.118 in.) or less 

   Fig 29: Identifying Steering Rack Boot No. 2 Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the boot.

SST 09521-24010 

HINT:

Perform the same procedure on the other side.

1. Using pliers, install the 2 boot clips.

1. Screw the lock nut and tie rod assembly LH on the rack end until the matchmarks are aligned.

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

   Fig 30: Aligning Tie Rod Assembly Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   After adjusting toe-in, torque the lock nut (See ADJUSTMENT ).

HINT:

Perform the same procedure on the other side.

1. Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
2. Using SST, install the left turn pressure tube to the steering link assembly.

   SST 09023-38201 

   Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

   HINT:

   • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
     Fig 31: Identifying Torque Wrench With Fulcrum Length

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • This torque value is effective when SST is parallel to a torque wrench.

1. Preform the same procedure on the other side.

   SST 09023-38201 

2. Install the tube clamp to the turn pressure tubes.