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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  POWER STEERING GEAR   ) 
  2. INSTALL STEERING RACK 
    1. Install SST to the rack.

      SST 09631-00350

      HINT:

      If necessary, scrape the burrs off the rack teeth end and burnish.

    2. Coat SST with power steering fluid.
    3. Install the rack into the rack housing.
    4. Remove the SST.
      Fig 1: Installing Steering Rack
      G03077114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL OIL SEAL 
    1. Install SST to the steering rack opposite end.

      SST 09631-00350

    2. Coat SST with power steering fluid.
    3. Coat a new oil seal lip with power steering fluid.
    4. Install the oil seal by pushing it onto the SST without tilting.
      NOTE: Make sure to install the oil seal facing the correct direction.
    5. Remove the SST.
      Fig 2: Installing Oil Seal
      G03077115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL SPACER AND CYLINDER END STOPPER 
    1. Install the spacer.
    2. Coat a new O-ring with power steering fluid, and install it to the stopper.
    3. Using a wooden block and hammer, drive in the stopper until it is tightly installed.
      NOTE: Be careful not to damage the O-ring.
      Fig 3: Driving In Stopper Using Wooden Block And Hammer
      G03077116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, torque the stopper.

      SST 09922-10010

      Torque: 110 N.m (1,122 kgf.cm, 81 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction as shown in Fig 4.

      HINT:

      Use a torque wrench with a fulcrum length of 380 mm (14.97 in.).

      Fig 4: Tightening Stopper Using SST
      G03077117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. AIR TIGHTNESS TEST 
    1. Install SST to the unions of 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.

      Fig 5: Testing Air Tightness
      G03077118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL CONTROL VALVE ASSEMBLY 
    1. Coat the teflon rings with power steering fluid.
    2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
      Fig 6: Winding Vinyl Tape On Serrated Part Of Control Valve Shaft
      G03077119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the valve assembly into the control valve housing.
      NOTE: Be careful not to damage the teflon rings and oil seal lip.
    4. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
    5. Using SST, torque the nut.

      SST 09631-20060

      Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

      NOTE: Be careful not to damage the oil seal lip.
      Fig 7: Tightening Nut Using SST
      G03077120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a punch, stake the nut.
      Fig 8: Staking Nut Using Punch
      G03077121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY 
    1. Coat a new O-ring with power steering fluid, and install it to the valve housing.
    2. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing.
    3. Torque the 2 bolts.

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

  8. INSTALL DUST COVER 
  9. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP 
    1. Apply sealant to 2 or 3 threads of the cap.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, 

      LOCTITE 242 or equivalent 

    2. Temporarily install the cap.
  10. 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. Torque the rack guide spring cap.

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

    3. Return the cap 19°.
      Fig 9: Returning Cap 19°
      G03077122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.

      SST 09616-00011

      Fig 10: Turning Control Valve Shaft Right & Left Using SST
      G03077123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the cap until the rack guide spring is not functioning.
    6. Using SST and a torque wrench, tighten the cap until the preload is within specification.

      SST 09616-00011

      Preload (turning): 

      1. Center Area: 1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf) 
      2. End Area: 1.3 - 1.7 N.m (13.3 - 17.3 kgf.cm, 11.5 - 15.0 in.lbf) 
      Fig 11: Tightening Cap Using SST & Torque Wrench
      G03077124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL RACK GUIDE SPRING CAP LOCK NUT 
    1. Apply sealant to 2 or 3 threads of the nut.

      Sealant: 

      Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

    2. Holding the rack guide spring cap rotating, and using SST, torque the nut.

      SST 09922-10010

      Torque: 52 N.m (520 kgf.cm, 38 ft.lbf) 

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

      HINT:

      Use a torque wrench with a fulcrum length of 345 mm (14.97 in.).

      Fig 12: Tightening Nut Using SST
      G03077125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Recheck the total preload.

      Preload (turning): 

      1. Center Area: 1.8 - 2.2 N.m (18.4 - 22.4 kgf.cm, 16.0 - 19.5 in.lbf) 
      2. End Area: 1.3 - 1.7 N.m (13.3 - 17.3 kgf.cm, 11.5 - 15.0 in.lbf) 
    4. Remove the RH and LH rack ends.
  12. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS 
    1. Install a new washer, and temporarily tighten the rack end.

      HINT:

      Align the claws of the washer with the steering rack grooves.

      Fig 13: Aligning Claws With Steering Rack Grooves
      G03077126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.

      SST 09922-10010

      Torque: 99 N.m (1,014 kgf.cm, 74 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction as shown in Fig 14.

      HINT:

      Use a torque wrench with a fulcrum length of 380 mm (13.58 in.).

      Fig 14: Tightening Rack End Using SST
      G03077127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and hammer, stake the washer.
      NOTE: Avoid any impact to the rack.
    4. Employ the same manner described above to the other side.
      Fig 15: Staking Washer Using Brass Bar & Hammer
      G03077128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS 
    1. Ensure that the tube hole is not clogged with grease.

      HINT:

      If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

      Fig 16: Identifying Tube Hole
      G03077129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the boot.
      NOTE: Be careful not to damage or twist the boot.
    3. Using pliers tighten a new clamp, as shown in Fig 17.
      Fig 17: Tightening Clamp Using Pliers
      G03077130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Employ the same manner described above to the other side.
  14. INSTALL 2 TURN PRESSURE TUBES 

    Using SST, install the tube.

    SST 09023-38201

    Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) 

    HINT:

    • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
    • This torque value is effective in case that SST is parallel to a torque wrench.
      Fig 18: Installing Turn Pressure Tubes
      G03077131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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