Power Steering Gear: Reassembly

NOTE: When using a vise, do not overtighten it.

COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See POWER STEERING GEAR )
INSTALL STEERING RACK
1. Install SST to the rack.
  SST 09631-10041
  
  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
INSTALL STEERING RACK BUSHING
1. Coat a new O-ring with power steering fluid and install it to the bushing.
  
  Fig 1: Installing SST To Steering Rack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
NOTE:
- Make sure that the bushing is installed facing in the correct direction.
- Be careful not to damage the oil seal lip.
INSTALL CYLINDER END STOPPER
1. Push into the cylinder end stopper.
2. Using needle nose pliers, install the snap ring.
Fig 2: Winding Vinyl Tape On Steering Rack End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
AIR TIGHTNESS TEST
1. Install SST to the rack housing.
  SST 09631-12071 (09633-00010)
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.

Fig 3: Installing SST To Rack Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL VALVE ASSEMBLY
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.
NOTE: Be careful not to damage the Teflon rings and oil seal lips.

Fig 4: Winding Vinyl Tape On Serrated Part Of Control Valve Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL SEAL OF CONTROL VALVE ASSEMBLY
1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
  SST 09612-22011
INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Install a new gasket.
  
  Fig 5: Installing Oil Seal Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the matchmarks on the control valve housing and rack housing.
3. Push into the control valve housing with control valve assembly.
4. Install the 2 bolts.
  Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
5. Install the dust seal.
Fig 6: Aligning Matchmarks On Control Valve Housing And Rack Housing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and install a new self-locking nut.

SST 09616-00010

Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
INSTALL RACK HOUSING CAP
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)
  
  Fig 7: Installing Self-Locking Nut Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a punch and a hammer, stake the 2 parts of the rack housing cap.
INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
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.
Fig 8: Staking Rack Housing Cap Using A Punch And Hammer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 9: Torquing Rack Guide Spring Cap Using A 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 10: Turning Control Valve Shaft Using SST
  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 09616-00010
  
  Preload (turning):
  
  0.8-1.3 N.m (8-13 kgf.cm, 6.9-11.3 in..lbf)
  
  Fig 11: Tightening Rack Guide Spring Cap Using SST And Hexagon Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
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 the illustration.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
  
  Fig 12: Tightening Rack Guide Spring Cap Lock Nut Using Hexagon Wrench And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Recheck the total preload.
  Preload (turning):
  
  0.8 - 1.3 N.m (8 - 13 kgf.cm, 6.9 - 11.3 in.lbf)
5. Remove the RH and LH rack ends.
INSTALL RH AND LH RACK ENDS
1. Temporarily install the LH rack end.
2. Using SST, hold the steering rack RH side 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 the illustration.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
3. Temporarily install the RH rack end.
  
  Fig 13: Tightening LH Rack End Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, hold the LH rack end 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 the illustration.

HINT:

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

Fig 14: Tightening RH Rack End Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
1. Ensure that the steering rack end hole is not clogged with grease.
  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.
  
  Fig 15: Identifying Steering Rack End Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage or twist the boot.
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 16: Tightening Clamp Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Employ the same manner described above to the other side.
3. After adjusting toe-in, torque the nut (See FRONT WHEEL ALIGNMENT ).
  Torque: 47 N.m (480 kgf.cm, 35 ft.lbf)
INSTALL TURN PRESSURE TUBES
1. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
  
  Fig 17: Aligning Matchmarks On Tie-Rod End And Lock Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the 2 turn pressure tubes.
  SST 09023-38200
  
  Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
  
  Fig 18: Installing Turn Pressure Tubes Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002