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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  .
  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.
      Fig 1: Pressing Oil Seal
      G01083062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal. SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360).

      Take care that the oil seal does not get reversed as you install it.

  3. Install Steering Rack 
      NOTE: If necessary, scrape the burrs off the steering rack teeth end and burnish.
      Fig 2: inspecting steering rack teeth & Installing SST 09631-16020
      G01083063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST to the steering rack. SST 09631-16020
    2. Coat SST with power steering fluid.
    3. Install the rack into the rack housing.
    4. Remove the SST.
  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: Identifying Bushing Installation Direction
      G01083064Courtesy 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.
      Fig 4: Installing Bushing Into Rack Housing
      G01083065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bushing into the rack housing.
  5. Install cylinder end stopper  :
    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 SST, turn the cylinder end stopper clockwise 150 ° 50°. SST 09631-10021.
  6. Air Tightness Test 
    1. Install SST to the rack housing. SST 09631-12071.
      Fig 5: Testing Air Tightness Of Rack Housing
      G01083066Courtesy 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. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
      Fig 6: Installing Control Valve Assembly
      G01083067Courtesy 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 control valve assembly into the control valve housing.
  8. 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.
      Fig 7: Installing Control Valve Oil Seal
      G01083068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal. SST 09612-22011.
  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 and rack housing.
      Fig 8: Aligning Control Valve & Rack Housing Matchmarks
      G01083069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)  .
  10. Install Self-Locking Nut 

    Using SST, stop the control valve shaft rotating and Install a new self-locking nut. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)  . SST 09616-00011.

    Fig 9: Installing Self-Locking Nut
    G01083070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Install Rack Housing Cap 
    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. Install the rack housing cap. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) 
    3. Using a punch and hammer, stake the 2 parts of the rack housing cap.
      Fig 10: Staking Rack Housing Cap
      G01083071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Install Rack Guide Subassembly, Conical Spring Washer, Rack Guide Spring And Rack Guide Spring Cap 
    1. Install the rack guide subassembly, conical spring washer 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.
  13. 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 (19 mm), install the rack guide spring cap.
      Fig 11: Adjusting Preload (1 Of 3)
      G01083072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
    3. Using a hexagon wrench (19 mm), return the cap 12°.
      Fig 12: Adjusting Preload (1 Of 3)
      G01083073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.
      1. SST 09616-00011
    5. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
    6. Using SST, a torque wrench and hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification. SST 09616-00011.

      Preload (turning):  0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf)

      Fig 13: Adjusting Preload (1 Of 3)
      G01083074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Install Rack Guide Spring Cap Lock Nut 
    1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
      1. Sealant: 
      2. Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent 
    2. Temporarily install the lock nut.
    3. Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut.Torque: 43 N.m (439 kgf.cm, 32 ft.lbf)  SST 09922-10010.
      Fig 14: Installing Rack Guide Spring Cap Lock Nut
      G01083075Courtesy 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)  : 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf).
    5. Remove the RH and LH rack ends.
  15. Install RH And LH claw washers and rack ends 
      NOTE: Align the claws of the washer with the steering rack grooves.
      Fig 15: Installing Claw Washers & Rack Ends
      G01083076Courtesy 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 the illustration. Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
      Fig 16: Installing Rack End
      G01083077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, torque the rack end. Torque: 62 N.m (633 kgf.cm, 46 ft.lbf)  . SST 09922-10010.
      3. CAUTION: Avoid any impact on the steering rack.
      Fig 17: Staking Claw Washer
      G01083078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, stake the washer.
    4. Employ the same manner described above to the other side.
  16. 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.
      Fig 18: Locating Steering Rack Hole
      G01083079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Make sure that the steering rack hole is not clogged with grease.
      2. CAUTION: Be careful not to damage or twist the boots.
    2. Install the boot clip and a new clamp.
    3. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010.
      Fig 19: Tightening Boot Clamps
      G01083080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Employ the same manner described above to the other side.
  17. 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.
      Fig 20: Aligning Tie Rod End & Rack End Matchmarks
      G01083081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. After adjusting toe-in, See SPECIFICATIONS & PROCEDURES in ALIGNMENT under STEERING. Torque the nut. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf) 
  18. Install 2 turn pressure tubes  :
    1. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
      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.
      Fig 21: Installing Pressure Tubes
      G01083082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the 2 tubes. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)  . SST 09023-38200.
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