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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 spacer and oil seal  :
    1. Coat a new oil seal lip with power steering fluid.
      2. NOTE:
      • Make sure that the oil seal is installed facing in the correct direction.
      • Take care that the oil seal does not get reversed as you install it.
    2. Using SST, press in the oil seal and spacer.
      1. SST 09951-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)
        Fig 1: Pressing Oil Seal And Spacer In
        G01026086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install steering rack  :
      NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
      Fig 2: Installing SST 09631-00350 & Identifying Rack Teeth
      G01026087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST to the rack.

      SST 09631-00350

    2. Coat SST with power steering fluid.
    3. Install the rack into the rack housing.
    4. Remove the SST.

      SST 09631-00350

  4. Install oil seal  :
    1. Install SST to the steering rack opposite end.

      SST 09631-00350

      Fig 3: Installing SST 09631-00350
      G01026088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat SST with power steering fluid.
    3. Coat a new oil seal lip with power steering fluid.
      4. NOTE: Make sure that the oil seal is installed facing in the correct direction.
    4. Install the oil seal by pushing it onto the SST without tilting.
    5. Remove the SST.

      SST 09631-00350

  5. Install cylinder end stopper  :
    1. Coat a new "O" ring with power steering fluid, and install it to the cylinder end stopper.
      2. 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.).

      Fig 4: Installing Cylinder End Stopper & Identifying Fulcrum Length Measurement
      G01026089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the cylinder end stopper.

      SST 09922-10010

      Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) 

    3. Using a punch and a hammer, stake the rack housing.
      Fig 5: Staking Rack Housing
      G01026090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Air tightness test  :
    1. Install SST to the unions of the rack housing.

      SST 09631-12071

      Fig 6: Testing Air Tightness Of Rack Housing
      G01026091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. 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. CAUTION: Be careful not to damage the teflon rings and oil seal lip.
      Fig 7: Installing Valve Assembly Into Control Valve Housing
      G01026092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the valve assembly into the control valve housing.
    4. Coat a new "O" ring with power steering fluid, and install it to the bearing guide nut.
      5. CAUTION: Be careful not to damage the oil seal lip.
      Fig 8: Removing & Installing Bearing Guide Nut
      G01026093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, install the bearing guide nut.

      SST 09631-20060

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

    6. Using a punch, stake the bearing guide nut.
      Fig 9: Staking Bearing Guide Nut
      G01026094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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 control valve housing and rack housing, and install the control valve housing with the control valve assembly to the rack housing.
    3. Install the 2 bolts.

      Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 

  9. Install dust cover  .
  10. 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: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
    3. Temporarily install the rack guide spring cap.
  11. 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.
      Fig 10: Adjusting Preload (1 Of 3)
      G01026095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
    3. Return the cap 19°.
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.

      SST 09616-00011

      Fig 11: Adjusting Preload (2 Of 3)
      G01026096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the cap until the rack guide spring is not functioning.
    6. Using SST and a torque wrench, tighten the cap until the preload is within specification.

      SST 09616-00011

      Fig 12: Adjusting Preload (3 Of 3)
      G01026097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (turning): 0.5 - 1.7 N.m (4.7 - 17.2 kgf.cm, 4.1 - 14.9 in..lbf) 

  12. INSTALL RACK GUIDE SPRING CAP LOCK NUT 
    1. Apply sealant to 2 or 3 threads of the lock nut.

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

      Fig 13: Install Rack Guide Spring Cap Lock Nut & Identifying Fulcrum Length Measurement
      G01026098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the lock nut.
      3. NOTE:
      • Use SST 09922-10010 in the direction shown in Fig 13.
      • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
    3. Holding the rack guide spring cap rotating, and using SST, torque the lock nut.

      SST 09922-10010

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

    4. Recheck the total preload.

      Preload (turning): 0.5 - 1.7 N.m (4.7 - 17.2 kgf.cm, 4.1 - 14.9 in..lbf)  .

    5. Remove the RH and LH rack ends.
  13. Install RH and LH claw washers and rack ends  :
      NOTE: Align the claws of the washer with the steering rack grooves.
      Fig 14: Installing Claw Washer
      G01026099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new claw washer, and temporarily tighten the rack end.
      2. 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.).
      Fig 15: Tightening Rack End
      G01026100Courtesy 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)  .

    3. Using a brass bar and a hammer, stake the washer.
      Fig 16: Staking Claw Washer
      G01026101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Avoid any impact on the rack.
    4. Employ the same manner described above to the other side.
  14. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS 
      NOTE: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
      Fig 17: Locating Steering Rack Hole
      G01026102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Ensure that the tube hole is not clogged with grease.
    2. Set a new clamp to the groove of the rack boot.
      3. CAUTION: Be careful not to damage or twist the boot.
      Fig 18: Installing Dust Boot
      G01026103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the boot, clip and a new clamp.
      4. NOTE: Face the projection to upper side of the vehicle.
      Fig 19: Identifying Proper Clamp Installation
      G01026104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten a new clamp, as shown in the illustration.
    5. Install the clip to the rack boot.
    6. Employ the same manner described above to the other side.
  15. 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 SPECIFICATIONS & PROCEDURES .

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

  16. Install 2 turn pressure tubes  :
    1. Install 4 new union seats to the rack housing and control valve housing.
      2. NOTE:
      • 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 20: Installing Turn Pressure Tubes
      G01026105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the 2 turn pressure tubes.

      SST 09023-38200

      Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) 

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