Steering Gear: Reassembly

CAUTION: When using a vise, do not over tighten it.

CAUTION: Be careful not to damage the teflon ring.

Install worm gear valve body assembly.See Figure. Coat 2 NEW "O" rings with power steering fluid and install them to the gear housing. Secure the gear housing on SST 09630-00014 (09631-00142) and clamp in vise. Install the valve body assembly while supporting the worm gear with your fingers so that it does not rotate. Torque the 4 bolts. Tighten to 45 ft. lbs. (61 N.m).

NOTE: Hold the worm gear to prevent it from turning. If rotating torque is not correct, replace the worm gear valve body assembly.

Fig 1: Checking Valve Body Assembly Rotating Torque

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST 09616-00010 and a torque wrench, check the valve body assembly rotating torque. Rotating torque should be 2.6-4.8 INCH lbs. (0.3-0.5 N.m). See Fig 1.
Install power piston plunger guide, power piston plunger, compression spring, an power piston plunger guide nut.Coat a new "O" ring with power steering fluid. Install the "O" ring to the plunger guide nut and install the plunger guide nut with a 10-mm hexagon wrench. See Fig 2. Tighten to 15 ft. lbs. (20 N.m).

Fig 2: Installing Plunger Guide Nut
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Determine center position. See Fig 3.Using SST 09616-00010, turn the worm gear valve body shaft so full lock in both directions and determine the exact center. Place matchmarks on the worm gear valve body shaft and worm gear valve body housing to show neutral position.

Fig 3: Determining Center Position
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NOTE: Fully loosen the cross shaft adjusting screw.

Fig 4: Installing Cross Shaft & Side Cover

Install cross shaft and side cover. See Fig 4. Coat a new "O" ring with power steering fluid and install it on the side cover. Assemble the cross shaft to the side cover. Install and push the cross shaft into the gear housing so that the center teeth mesh together. Torque the 4 bolts in a diagonal pattern. Tighten to 45 ft. lbs. (61 N.m).
Adjust total preload. See Fig 5. Install SST 09616-00010 with a torque wrench on the worm gear valve body shaft. Turn the cross shaft adjusting screw until the preload is within specification. Preload should be 6.5-9.6 INCH lbs. (0.74-1.08 N.m).

Fig 5: Adjusting Total Preload
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install new seal washer.
Install adjusting screw lock nut. Torque the lock nut while holding the cross shaft adjusting screw. Tighten to 34 ft. lbs. (46 N.m).
Recheck total preload.