Power Steering Gear: Reassembly

1. Install SST to the rack.
   1. SST 09631-16020
   Fig 1: Using SST To Protect Rack Teeth
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
2. Coat SST with power steering fluid.
3. Install the steering rack into the rack housing.
4. Remove the SST.
   1. SST 09631-16020

1. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
2. Coat a new oil seal lip with power steering fluid.
3. Install the oil seal by pushing it into the rack housing without tilting.
Fig 2: Installing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, drive in the cylinder end stopper.
   1. SST 09612-22011
      Fig 3: Installing Cylinder Head End Stopper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, install a new snap ring to the rack housing.

1. Install SST to the rack housing.
   1. SST 09631-12071
   Fig 4: Displaying Air Tightness Test
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply 53 kPa (400 mm Hg, 15.75 in. Hg) of vacuum for about 30 seconds.
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.

Install the control valve assembly into the rack housing.

1. Coat a new bearing with molybdenum disulfide lithium base grease.
2. Using SST, press in the bearing to the rack housing.
   1. SST 09612-22011

1. Coat a new oil seal lip with power steering fluid.
   Fig 5: Identifying Bearing & SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, press in the oil seal.
   1. SST 09612-22011
   NOTE: Make sure to install the oil seal facing in the correct direction.
3. Using snap ring pliers, install a new snap ring to the rack housing.
   Fig 6: Identifying Oil Seal & SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, stop the control valve shaft rotating and install a new self- locking nut.
   1. SST 09616-00011
   2. Torque: 12 N.m (125 kgf. cm, 9 ft. lbf) 
   Fig 7: Installing Self-Locking Nut
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn "C" of SST to measure the dimension "A," then set SST as shown in Fig 8.
   1. SST 09613-12020
      Fig 8: Locating A, B & C

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Dimension A: 16.5 - 17.0 mm (0.65 - 0.67 in.) 
3. Stake the self-locking nut by turning "B" of the SST until it touches the spacer of the SST.

1. Apply sealant to 2 or 3 threads of the rack housing cap.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Install the rack housing cap.
   1. Torque: 69 N.m (700 kgf. cm, 51 ft. lbf) 

1. Install the rack guide, conical spring and rack guide spring.
   Fig 9: Identifying Conical Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure to install the conical spring facing in the correct direction.
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.

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 (21 mm), torque the rack guide spring cap.
   1. Torque: 25 N.m (250 kgf. cm, 18 ft. lbf) 
3. Using a hexagon wrench (21 mm), return the rack guide spring cap 12°.
   Fig 10: Returning Rack Guide Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
   1. SST 09616-00011
      Fig 11: Turning Control Valve Shaft Right & Left

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a hexagon wrench (21 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
6. Using SST, a torque wrench and a hexagon wrench (21 mm), tighten the rack guide spring cap until the preload is within the specification.
   1. SST 09616-00011
      Fig 12: Tightening Rack Guide Spring Cap

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Preload (turning): 1.1 -1.6 N.m (11 - 16 kgf. cm, 9.7 - 14.2 in. lbf) 

1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
2. Temporarily install the rack guide spring cap lock nut.
3. Using a hexagon wrench (21 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
   1. SST 09922-10011
   2. Torque: 32 N.m (330 kgf. cm, 24 ft. lbf) 
   NOTE: Use SST 09922-10010 in the direction shown in Fig 13.
   Fig 13: Displaying Hexagon Wrench & Fulcrum Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

4. Recheck the total preload.
   1. Preload (turning): 1.1 - 1.6 N.m (11 - 16 kgf. cm, 9.7 - 14.2 in. lbf) 
5. Remove the RH and LH rack ends.

1. Install a new claw washer, and temporarily install the rack end.
   Fig 14: Identifying Rack End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Align the claws of the claw washer with the steering rack grooves.
2. Using a spanner (22 mm), hold the steering rack steadily and using SST, torque the rack end.
   1. SST 09922-10010
      Fig 15: Using Spanner & SST To Torque Rack End

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Torque: 60 N.m (615 kgf. cm, 44 ft. lbf) 
   NOTE: Use SST 09922-10010 in the direction shown in Fig 15.
   NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
3. Using a brass bar and a hammer, stake the washer.
   Fig 16: Using Brass Bar To Stake Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Avoid any impact on the steering rack.
4. Employ the same manner described above to the other side.

1. Install the grommet to the No. 1 rack housing bracket.
2. Align the matchmarks on the bracket and housing.
3. Install and torque the bolt.
   1. Torque: 61 N.m (620 kgf. cm, 45 ft. lbf) 
   Fig 17: Aligning Bracket & Housing Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Ensure that the steering rack hole is not clogged with grease.
   NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
2. Install the boot, clip and a new clamp.
   NOTE: Be careful not to damage or twist the boot.
   Fig 18: Installing Boot, Clip & new Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the clamp as shown in Fig 19.
   Fig 19: Tightening Clamps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Employ the same manner described above to the other side.

1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
   Fig 20: Locating & Aligning Matchmarks

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Employ the same manner described above to the other side.
3. After adjusting toe-in, torque the nut (See BLEEDING ).
   1. Torque: 74 N.m (750 kgf. cm, 54 ft. lbf) 

Fig 21: Installing Turn Pressure Tubes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST, install the 2 turn pressure tubes.

1. SST 09023-38200
2. Torque: 27 N.m (270 kgf. cm, 20 ft. lbf)