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 COMPONENTS )
INSTALL SPACER AND OIL SEAL
1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the spacer and oil seal.
  
  Fig 1: Installing Spacer & Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09951-60010 (09951-00350, 09951-00550, 09952-06010), 09950-70010 (09951-07360)
NOTE:
- Make sure to install the oil seal facing the correct direction.
- Take care that the oil seal does not get reversed as you install it.
INSTALL STEERING RACK
1. Install SST to the rack.
  SST 09631-00350
  
  NOTE: 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 2: Installing SST To Rack
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 3: Installing Oil Seal Onto SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the SST.
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 4: Installing Spacer & Cylinder End Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, torque the stopper.
  
  Fig 5: Identifying Torque Wrench Fulcrum Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09922-10010
  
  Torque: 66 N.m (670 kgf.cm, 48 ft.lbf)
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.).
AIR TIGHTNESS TEST
1. Install SST to the unions of the rack housing.
  SST 09631-12071
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 change in the vacuum, check the installation of the oil seals.

Fig 6: Testing Air Tightness
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Push the valve assembly into the control valve housing.
  NOTE: Be careful not to damage the teflon rings and oil seal lip.
  
  Fig 7: Pushing Taped Valve Assembly Into Control Valve Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: 25 N.m (250 kgf.cm, 18 ft.lbf)
  
  Fig 8: Installing Bearing Guide Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful not to damage the oil seal lip.
6. Using a punch, stake the nut.
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)
INSTALL DUST COVER
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.
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 10: Installing Rack Guide Spring Cap
  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. Loosen the cap until the rack guide spring is not functioning.
  
  Fig 11: Rotating Control Valve Shaft Right & Left
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a torque wrench, tighten the cap until the preload is within specification.
  SST 09616-00011
  
  Fig 12: Tightening Rack Guide Spring Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Preload (turning):
  
  1.3 - 1.8 N.m (13.3 - 18.4 kgf.cm, 11.5 - 16.0 in.lbf)
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: 51 N.m (520 kgf.cm, 38 ft.lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
  
  Fig 13: Identifying Torque Wrench Fulcrum Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Recheck the total preload.
  Preload (turning):
  
  1.3 - 1.8 N.m (13.3 - 18.4 kgf.cm, 11.5 - 16.0 in.lbf)
4. Remove the RH and LH rack ends.
INSTALL RH AND LH CLAW WASHERS AND RACK ENDS
1. Install a new washer, and temporarily tighten the rack end.
  NOTE: Align the claws of the washer with the steering rack grooves.
  
  Fig 14: Identifying Steering Rack Grooves
  Courtesy 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: 76 N.m (770 kgf.cm, 56 ft.lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
  
  Fig 15: Identifying Torque Wrench Fulcrum Length
  Courtesy 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 16: Staking Claw Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
1. Ensure that the tube hole is not clogged with grease.
  NOTE: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
  
  Fig 17: Locating Tube Hole
  Courtesy 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 the illustration.
4. Employ the same manner described above to the other side.
Fig 18: Tightening Boot Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TUBE SUPPORT RETAINER
Torque the bolt.

Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
INSTALL 2 TURN PRESSURE TUBES
Using SST, install the tube.

SST 09023-38200

Torque: 23 N.m (230 kgf.cm, 17 ft.lbf)
NOTE:
- 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 19: Installing Pressure Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002