Power Steering Gear: Reassembly

WARNING: This page is about a different car, the 2002 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

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

Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease . See Figure and Figure .
Install oil seal :
1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.
  NOTE:
  - Make sure to install the oil seal facing in the correct direction.
  - Take care that the oil seal does not get reversed as you install it.
  Fig 1: Installing Rack Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-60010 (09951-00330, 09951-00490,09952-06010), 09950-70010 (09951-07360)
Install steering rack .
1. Install SST to the rack. SST 09631-20051.
  NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
  
  Fig 2: Installing SST 09631-20051 & Identifying Rack Teeth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the SST with power steering fluid.
3. Install the steering rack into the rack housing.
  CAUTION: Be careful not to damage the oil seal lip.
4. Remove the SST. SST 09631-20051.
Install bushing .
1. Coat a new "O" ring with power steering fluid and install it to the bushing.
2. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
3. Install the bushing.
  CAUTION:
  - Make sure to install the bushing facing in the correct direction.
  - Be careful not to damage the oil seal lip.
  Fig 3: Identifying Bushing Installation Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install cylinder end stopper .
1. Align the installation hole for the wire of the stopper with the slot of the rack housing.
  
  Fig 4: Installing Cylinder End Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install a new wire into the stopper.
3. Using SST, turn the stopper clockwise 450 +/- 50°. SST 09631-16010.
Air tightness test .
1. Install SST to the rack housing. SST 09631-12071.
  
  Fig 5: Testing Air Tightness Of Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
Install control valve assembly .
1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
  
  Fig 6: Installing Control Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the teflon rings with power steering fluid.
3. Install the valve assembly into the valve housing.
  CAUTION: Be careful not to damage the teflon rings and oil seal.
Install oil seal .
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. Place a new gasket on the rack housing.
2. Align the matchmarks on the control valve housing with control valve assembly and rack housing.
3. Install the 2 bolts.
  Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) .
Install nut .
Using SST to stop the control valve shaft rotating, install a new self-locking nut. SST 09616-00011.

Torque: 30 N.m (300 kgf.cm, 22 ft.lbf)

Fig 8: Installing Self-Locking Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install dust cover .
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. Using SST, install the rack housing cap. SST 09816-30010.
  Torque: 59 N.m (600 kgf.cm, 43 ft.lbf)
  
  Fig 9: Installing Rack Housing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a punch and hammer, stake the 2 parts of the cap.
  
  Fig 10: Staking Rack Housing Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rack guide, rack guide spring and rack guide spring cap .
1. Install the rack guide 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.
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, install the rack guide spring cap.
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
3. Using a hexagon wrench, return the rack guide spring cap 12°.
  
  Fig 11: Adjusting Preload (1 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011.
  
  Fig 12: Adjusting Preload (2 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning.
6. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616-00011.
  Preload (turning): 1.0 - 1.45 N.m (10 - 14.5 kgf.cm, 8.7 -12.6 in.lbf) .
  
  Fig 13: Adjusting Preload (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install rack guide spring cap lock nut .
1. Apply sealant to 2 or 3 threads of the lock nut.
  Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
2. Temporarily install the lock nut.
3. Using a hexagon wrench to hold the rack guide spring cap, and using SST, torque the lock nut. SST 09922-10010.
  NOTE: Use SST 09922-10010 in the direction shown in Fig 14.
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
  
  Torque: 51 N.m (520 kgf.cm, 38 ft.lbf)
  
  Fig 14: Installing Rack Guide Spring Cap Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Recheck the total preload.
  Preload (turning): 1.0 -1.45 N.m (10 -14.5 kgf.cm, 8.7 -12.6 in..lbf) .
5. Remove the RH and LH rack ends.
Install RH and LH claw washers and rack ends .
1. Install a new claw washer, and temporarily install the rack end.
  NOTE: Align the claws of the claw washer with the steering rack grooves.
  
  Fig 15: Installing Claw Washers & Rack Ends
  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.
  NOTE: Use SST 09922-10010 in the direction shown in Fig 16.
  Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
  
  Torque: 76 N.m (770 kgf.cm, 56 ft.lbf)
  
  Fig 16: Installing Rack End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, stake the washer.
  CAUTION: Avoid any impact on the rack.
  
  Fig 17: Staking Claw Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Employ the same manner described above to the other side.
Install RH and LH rack boots, clamps and clips .
1. Ensure that the steering rack hole is not clogged with grease.
  NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
  
  Fig 18: Locating Steering Rack Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set a new clamp to the groove of the rack boot.
3. Install the boot.
  CAUTION: Be careful not to damage or twist the boot.
4. Using SST, tighten the clamp as shown in Fig 19. SST 09521-24010.
  
  Fig 19: Tightening Boot Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the clip to the rack boot.
6. Employ the same manner described above to the other side.
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. After adjusting toe-in, torque the nut. See SPECIFICATIONS & PROCEDURES .
  Torque: 55 N.m (560 kgf.cm, 41 ft.lbf)
Install 2 turn pressure tubes .
1. Coat 4 new "O" rings with power steering fluid and install them to the turn pressure tubes.
2. Using SST, install the 2 turn pressure tubes. SST 09023-12700.
  Torque: 12 N.m (117 kgf.cm, 9 ft.lbf)
  
  Fig 20: Installing Pressure Tubes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
  - This torque value is effective in case that SST is parallel to a torque wrench.