Power Steering Gear: Reassembly

1. Apply power steering fluid to a new oil seal, and install the oil seal on the rack housing at an angle.
   NOTE: Install the oil seal in the correct direction.

   HINT:

   Install the oil seal so that the port faces downward with approximately 15 degrees.

2. Using SST, push in the oil seal by hand until it passes through the 2 ports.

   SST 09631-00180, 09950-70010 (09951-07360)

   NOTE: Do not turn SST when inserting the oil seal.
   Fig 1: Installing Oil Seal On Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. After the oil seal has passed through the ports, push in the oil seal by hand until it becomes level, using SST.

   SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

   NOTE: When SST is set, do not damage the inside surface of the rack housing.
   Fig 2: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. After the oil seal has become level, using SST and press, install the oil seal.

   SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

5. Coat new oil seal lip with power steering fluid.
6. Using needle nose pliers, install the bush to the rack housing.
   Fig 3: Installing Bush To Rack Housing

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1. Coat a new power piston O-ring with power steering fluid and install it to the steering rack.
2. Coat a new power piston oil seal with power steering fluid.
3. Expand the power piston oil seal with your fingers.
   NOTE: Be careful not to over expand the power piston oil seal.
   Fig 4: Expanding Power Piston Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the power piston oil seal to the steering rack, and settle it down with your fingers.
   Fig 5: Installing Power Piston Oil Seal To Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install SST to the steering rack.

   SST 09631-20102

   HINT:

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

Fig 6: Installing SST To Steering Rack
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Coat the SST with power steering fluid.
7. Install the steering rack into the rack housing.
8. Remove the SST.

   SST 09631-20102

1. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
2. Coat a new cylinder end stopper oil seal lip with power steering fluid.
3. Install the cylinder end stopper oil seal by pushing it into the rack housing without tilting.
   NOTE:

   • Make sure that the oil seal is installed facing in the correct direction.
   • Be careful not to damage the oil seal lip.
   Fig 7: Installing Cylinder End Stopper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat a new O-ring with power steering fluid.
5. Install the O-ring to the cylinder end stopper.
6. Install a new rack guide bush to the cylinder end stopper.
7. Apply molybdenum disulfide lithium base grease to the inside of the bush.
   Fig 8: Applying Molybdenum Disulfide Lithium Base Grease To Inside Of Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Place rack housing in vise.
   NOTE: Hold the arrow part in the illustration in a vise.
9. Using SST, install the cylinder end stopper to rack housing.

   SST 09631-20120

   Torque: 60 N.m (612 kgf.cm, 44 ft.lbf) 

   Fig 9: Installing Cylinder End Stopper To Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   SST 09631-12071 (09633-00010)

2. Apply vacuum of 53 kPa (400 mm Hg, 15.75 in. Hg) 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 10: Inspecting Rack & Pinion Power Steering Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the teflon rings and oil seal lip with power steering fluid.
2. Coat the bearing with molybdenum disulfide lithium base grease.
3. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
4. Using SST, press the control valve assembly into the control valve housing.

   SST 09612-22011

   Fig 11: Pressing Control Valve Assembly Into Control Valve Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the teflon rings and oil seal lips.

1. Install a new gasket.
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: 18 N.m (185 kgf.cm, 13 ft.lbf) 

   Fig 12: Aligning Matchmarks On Control Valve Housing & Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply molybdenum lithium base grease to the contact surface of the power steering rack and of the rack guide.
2. Install the rack guide and compression spring to the rack housing.
3. 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 

4. 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 (24 mm), torque the rack guide spring cap.

   Torque: 83 N.m (851 kgf.cm, 62 ft.lbf) 

3. Using a hexagon wrench (19 mm), return the rack guide spring cap 12°
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
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 hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification.

   SST 09616-00010

   Preload (turning): 1.0 to 1.6 N.m (10 to 17 kgf.cm, 9 to 15 in.lbf) 

1. Install 2 new claw washers, and temporally install the rack ends. See Fig 13.

   HINT:

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

2. Apply MP grease to the rack end ball joint.
3. Using 2 SST, install the rack end sub-assy (RH side).

   SST 09922-10010

   Torque: 72 N.m (736 kgf.cm, 53 ft.lbf) 

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

   HINT:

   • Using SST, hold the rack and install the rack end sub-assy.
   • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
4. Using SST and a spanner (22 mm), tighten the rack end (LH side).

   Torque: 72 N.m (736 kgf.cm, 53 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.
   Fig 13: Tightening Rack End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Using SST, hold the rack and install the rack end.
   • Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).
5. Using a brass bar and a hammer, stake the 2 claw washers.
   NOTE: Avoid any impact to the steering rack.
   Fig 14: Staking Claw Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Ensure that the steering rack hole is not clogged with grease.

   HINT:

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

   Fig 15: Identifying Rack Hole

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1. Apply silicon grease to the inside small caliber of steering rack boots No. 2
2. Install the steering rack boots No. 2 to the groove on the rack housing.

HINT:

Install the rack boot No. 1 by the same procedures with rack boot No. 2.

Fig 16: Applying Silicon Grease To Inside Small Caliber Of Steering Rack Boots No. 2

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers and a screwdriver, install a new rack boot No. 2 clamp. See Fig 17.
   NOTE: Be careful not to damage or twist the rack boot.

HINT:

Install the rack boot No. 1 clamp by the same procedures with rack boot No. 2 clamp.

Fig 17: Installing Rack Boot No. 2 Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers, install the 2 boot clips.
2. Using SST, turn the control valve, and check that the rack boots expand and contract smoothly.

   SST 09616-00011

   Fig 18: Checking Movement Of Rack Boots

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Screw the lock nut and tie rod end sub-assy LH onto the rack end until the matchmarks are aligned. See Fig 19.

   HINT:

   After adjusting toe-in, torque the lock nut.

HINT:

Install the RH side by the same procedures with LH side.

Fig 19: Aligning Match Mark Between Lock Nut & Tie Rod End Sub-Assy

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002