Power Steering Gear: Reassembly

1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
   Fig 1: Pressing In Oil Seal Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

1. Install SST to the steering rack.

   SST 09631-33010

   NOTE: If necessary, scrape the burrs off the steering rack teeth end and burnish.
2. Coat the SST with power steering fluid.
3. Install the steering rack into the rack housing.
   Fig 2: Installing Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the oil seal lip.
4. Remove SST.

   SST 09631-33010

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.
3. Install the bushing.
Fig 3: Installing Bushing
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 SST, turn the cylinder end stopper clockwise 450 +/- 50°.
   Fig 4: Installing Cylinder End Stopper Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09631-10021

Fig 5: Testing Air Tightness

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   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.

1. Install the rack housing No. 2 grommet to the rack housing No. 2 bracket.
   Fig 6: Installing Rack Housing No. 2 Grommet To Rack Housing No. 2 Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Align the projection of the rack housing No. 2 grommet with the hole of the rack housing No. 2 bracket.
2. Align the matchmarks on the rack housing No. 2 bracket and rack housing.
3. Place the rack housing No. 2 bracket in a vise and install the vise to fasten the clamp.

Fig 7: Placing Rack Housing No. 2 Bracket In Vise

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
2. Coat the teflon rings with power steering fluid.
3. Install the control valve assembly into the control valve housing.
Fig 8: Installing Control Valve Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
   Fig 9: Pressing In Oil Seal Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09612-22011

1. Place a new gasket on the rack housing.
2. Align the matchmarks on the control valve housing and rack housing.
3. Install the 2 bolts.

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

Using SST, stop the control valve shaft rotating and install a new self-locking nut.

Fig 10: Installing Self-Locking Nut Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09616-00011

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

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 11: Installing Rack Housing Cap Using A Punch & Hammer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rack guide sub- assembly and rack guide spring.
2. Apply sealant to 2 or 3 threads of the rack guide spring cap.

   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 SST, torque the rack guide spring cap.
   Fig 12: Torquing Rack Guide Spring Cap Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09631-10021

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

3. Using SST, return the rack guide spring cap 12°.
   Fig 13: Turning Rack Guide Spring Cap 12° Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09631-10021

4. Using SST, turn the control valve shaft right and left 1 or 2 times.
   Fig 14: Turning Control Valve Shaft Right & Left Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09616-00011

5. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning.

   SST 09631-10021

6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
   Fig 15: Tightening Rack Guide Spring Cap Using SST & A Torque Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09616-00011, 09631-10021

   Preload (turning): 

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

1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.

   Sealant: 

   Part No.08833-00080, THREE BOND 1344, 

   LOCTITE 242 or equivalent 

2. Temporarily install the rack guide spring cap lock nut.
3. Using SST, hold the rack guide spring cap and using another SST torque the rack guide spring cap lock nut.
   Fig 16: Installing Rack Guide Spring Cap Lock Nut Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09631-10021, 09922-10010

   Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   NOTE: 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.

1. Install a new claw washer, and temporarily install the rack ends.
   Fig 17: Installing New Claw Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Align the claws of the claw washers with the steering rack grooves.
2. Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end.
   Fig 18: Torquing Rack End Using A Spanner

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09922-10010

   Torque: 60 N.m (610 kgf.cm, 44 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
3. Using a brass bar and hammer, stake the claw washer.
   Fig 19: Staking Claw Washer Using A Brass Bar & Hammer

   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. Ensure that the steering rack hole is not clogged with grease.
   NOTE: If the hole is clogged, the pressure inside the rack boot will change after it is assembled and the steering wheel is turned.
   Fig 20: Locating Steering Rack Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rack boot, clip and a new clamp.
   NOTE: Be careful not to damage or twist the rack boot.
3. Using SST, tighten the clamp as shown in the illustration.
   Fig 21: Tightening Clamp Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09521-24010

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

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

3. Employ the same manner described above to the other side.

Fig 22: Aligning Match Mark

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
2. Using SST, install the 2 turn pressure tubes.
   Fig 23: Installing Turn Pressure Tubes Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09023-38200

   Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)