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 And Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09951-60010 (09951-00350, 09951-00550,
  
  09952-06010), 09950-70010 (09951-07360)
  CAUTION:
  - 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.
  
  Fig 2: Installing Steering Rack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSTALL OIL SEAL
1. Install SST to the steering rack opposite end.
  
  Fig 3: Installing Steering Rack Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
  CAUTION: Make sure to install the oil seal facing the correct direction.
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.
  
  Fig 4: installing Stopper With Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  CAUTION: Be careful not to damage the O-ring.
4. Using SST, torque the stopper.
  
  Fig 5: Using SST To Torque The Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09922-10010
  
  Torque: 66 N.m (670 kgf.cm, 48 ft.lbf)
  
  CAUTION: Use SST 09922-10010 in the direction shown in Fig 5.
  
  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.
  
  Fig 6: Testing Air Tightness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
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 7: Applying Vinyl Tape On Serrated Part Of Control Valve Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Push the valve assembly into the control valve housing.
  CAUTION: 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.
  
  Fig 8: Using SST To Torque Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09631-20060
  
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
  
  CAUTION: Be careful not to damage the oil seal lip.
6. Using a punch, stake the nut.
  
  Fig 9: Using A Punch To Stake Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. (b) 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.
  
  Fig 10: Torque Rack Guide Spring Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
3. Return the cap 19°.
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
  
  Fig 11: Using SST Turn Control Valve Shaft Right And Left 1 Or 2 Times
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09616-00011
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.
  
  Fig 12: Using SST To Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09616-00011
  
  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.
  
  Fig 13: Installing Rack Guide Spring Cap Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09922-10010
  
  Torque: 51 N.m (520 kgf.cm, 38 ft.lbf)
  
  CAUTION: Use SST 09922-10010 in the direction shown in Fig 13.
  
  NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
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.
  
  Fig 14: Installing New Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Align the claws of the washer with the steering rack grooves.
2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
  
  Fig 15: Using SST To Torque Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09922-10010
  
  Torque: 76 N.m (770 kgf.cm, 56 ft.lbf)
  
  CAUTION: Use SST 09922-10010 in the direction shown in Fig 15.
  
  NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
3. Using a brass bar and hammer, stake the washer.
  
  Fig 16: Staking Washer With Brass Bar And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  CAUTION: Avoid any impact to the rack.
4. Employ the same manner described above to the other side.
INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
1. Ensure that the tube hole is not clogged with grease.
  
  Fig 17: Checking Tube Hole Is Clear Of Grease
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
2. Install the boot.
  CAUTION: Be careful not to damage or twist the boot.
3. Using pliers tighten a new clamp, as shown in Fig 18.
  
  Fig 18: Using Pliers To Tighten New Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Employ the same manner described above to the other side.
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 2 Turn Pressure Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002