Power Steering Gear: Reassembly

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 Using SST

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1. Install SST to the rack.

   SST 09631-10041

   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.

SST 09631-10041

Fig 2: Installing Steering Rack Using SST

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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 into the rack housing.

Fig 3: Installing Bush Into Rack Housing

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1. Push into the cylinder end stopper.
2. Using needle nose pliers, install the snap ring.

1. Install SST to the rack housing.

   SST 09631-12071 (09633-00010)

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.

Fig 4: Testing Air Tightness Using SST

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1. Install a new gasket.
2. Align the matchmarks on the control valve housing and rack housing.
3. Push into the control valve assembly.
4. Install the 2 bolts.

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

Fig 5: Aligning Matchmarks

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1. Install the rack guide sub-assembly, rack guide spring spacer and rack guide spring.
   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.
   Fig 6: Installing Rack Guide Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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 (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: Returning Rack Guide Spring Cap Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times.

   SST 09616-00011

5. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
   Fig 8: Turning Control Valve Shaft Right And Left Using Hexagon Wrench

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Using SST

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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 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

   Torq.m (290 kgf.cm, 21 ft.lbf) 

   Fig 10: Holding Rack Guide Spring Cap And Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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): 

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

5. Remove the 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

   Torq.m (630 kgf.cm, 46 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   NOTE: Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
3. Temporarily install the LH rack end.
   Fig 11: Holding Steering Rack LH Side Using SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, hold the RH rack end steadily and using another SST, torque the LH rack end.

   SST 09922-10010

   Torq.m (630 kgf.cm, 46 ft.lbf) 

Fig 12: Holding RH Rack Using SST

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1. Ensure that the steering rack end 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 13: Identifying Steering Rack End Hole

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3. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010
4. Employ the same manner described above to the other side.

Fig 14: Tightening Clamp Using SST

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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 FRONT WHEEL ALIGNMENT ).

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

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

Fig 15: Identifying Matchmarks

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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

   Torq.m (110 kgf.cm, 8 ft.lbf) 

Fig 16: Installing Turn Pressure Tubes Using SST

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