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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 OIL SEAL 
    1. Coat a new oil seal lip with power steering fluid.
    2. Install the oil seal to SST, and press them into the rack housing.

      SST 09950-60010 (09951-00210, 09951-00370, 09952-06010), 09950-70010 (09951-07360)

      Fig 1: Installing Oil Seal Into Rack Housing
      G02906699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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. 
  3. INSTALL STEERING RACK 
    1. Install SST to the rack.

      SST 09631-10041

      Fig 2: Installing SST To Rack
      G02906700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      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.

      SST 09631-10041

  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: Winding Vinyl Tape On Steering Rack End
      G02906701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bushing into the rack housing.
      NOTE:
      • Make sure that the bushing is installed facing in the correct direction. 
      • Be careful not to damage the oil seal lip. 
  5. INSTALL CYLINDER END STOPPER 
    1. Push into the cylinder end stopper.
    2. Using needle nose pliers, install the snap ring.
  6. AIR TIGHTNESS TEST 
    1. Install SST to the rack housing.

      SST 09631-12071 (09633-00010)

      Fig 4: Installing SST To Rack Housing
      G02906702Courtesy 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 a change in the vacuum, check the installation of the oil seals.

  7. INSTALL CONTROL VALVE ASSEMBLY 
    1. Install a new gasket.
    2. Align the matchmarks on the control valve housing and rack housing.
      Fig 5: Aligning Matchmarks On Control Valve Housing & Rack Housing
      G02906703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push into the control valve assembly.
    4. Install the 2 bolts.

      Torque:  21 N.m (220 kgf.cm, 15 ft.lbf)

  8. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING SPACER, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP 
    1. Install the rack guide sub-assembly, rack guide spring spacer and rack guide spring.
      Fig 6: Installing Rack Guide Sub-Assembly, Rack Guide Spring Spacer & Rack Guide Spring
      G02906704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the rack guide spring spacer is installed facing in the correct direction. 
    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.
  9. 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), torque the rack guide spring cap.

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

    3. Using a hexagon wrench (19 mm), return the rack guide spring cap 12°.
      Fig 7: Tightening Rack Guide Spring Cap
      G02906705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.

      SST 09616-0001 1

      Fig 8: Turning Control Valve Shaft Right & Left Using SST
      G02906706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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):  1.2 - 1.4 N.m (12 - 14 kgf.cm, 10.4 - 12.2 in.lbf)

      Fig 9: Tightening Rack Guide Spring Cap
      G02906707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL RACK GUIDE SPRING CAP LOCK NUT 
    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

      Fig 10: Applying Sealant To Threads Of Rack Guide Spring Cap Lock Nut
      G02906708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the rack guide spring cap lock nut.
    3. Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.

      SST 09922-10010

      Torque:  28 N.m (290 kgf.cm, 21 ft.lbf)

      NOTE: Use SST 09922-10010 in the direction shown in  Fig 10  . 

      HINT:

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

    4. Recheck the total preload.

      Preload (turning):  1.2 - 1.4 N.m (12 - 14 kgf.cm, 10.4 - 12.2 in.lbf)

    5. Remove the RH and LH rack ends.
  11. INSTALL RH AND LH RACK ENDS 
    1. Temporarily install the RH rack end.
    2. Using SST, hold the steering rack LH side steadily and using another SST, torque the RH rack end.

      SST 09922-10010

      Torque:  62 N.m (630 kgf.cm, 46 ft.lbf)

      NOTE: Use SST 09922-10010 in the direction shown in  Fig 11  . 
      Fig 11: Holding Steering Rack LH Side
      G02906709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).

    3. Temporarily install the LH rack end.
    4. Using SST, hold the RH rack end steadily and using another SST, torque the LH rack end.

      SST 09922-10010

      Torque:  62 N.m (630 kgf.cm, 46 ft.lbf)

      NOTE: Use SST 09922-10010 in the direction shown in  Fig 12  . 
      Fig 12: Holding RH Rack End Steadily
      G02906710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).

  12. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS 
    1. Ensure that the steering rack end hole is not clogged with grease.
      Fig 13: Ensuring Steering Rack End Hole Is Not Clogged
      G02906711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      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. 
    3. Using SST, tighten the clamp as shown in Fig 14 .

      SST 09521-24010

      Fig 14: Tightening Clamp Using SST
      G02906712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Employ the same manner described above to the other side.
  13. 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 15: Aligning Lock Nut & Tie Rod End Matchmarks
      G02906713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. After adjusting toe-in, torque the nut (See INSPECTION ).

      Torque:  47 N.m (480 kgf.cm, 35 ft.lbf)

    3. Employ the same manner described above to the other side.
  14. INSTALL 2 TURN PRESSURE TUBES 
    1. Coat 4 new O-rings with power steering fluid and install them to 2 turn pressure tubes.
    2. Using SST, install the 2 turn pressure tubes.

      SST 09023-38200

      Torque:  11 N.m (110 kgf.cm, 8 ft.lbf)

      Fig 16: Installing Pressure Tubes
      G02906714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • 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.
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