Power Steering Link: Reassembly

1. Coat a new O-ring with power steering fluid and install it on steering rack.
2. Expand a new teflon ring with your fingers.
   NOTE: Be careful not to overexpand the teflon ring.
3. Coat the teflon ring with power steering fluid.
   Fig 1: Expanding Teflon Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the teflon ring to the steering rack, and settle it down with your fingers.

Fig 2: Installing Teflon Ring To Steering Rack

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat SST with power steering fluid.
2. Install SST to the rack.

   SST 09631-00350 

   HINT:

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

3. Install the rack into the rack housing.
   Fig 3: Identifying Rack Teeth End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat SST with power steering fluid.

   SST 09631-00350 

5. Install SST to the steering rack opposite end.
6. Coat a new oil seal lip with power steering fluid, and install the oil seal by pushing it without tilting.
   NOTE:

   • Make sure to install the oil seal facing in the correct direction.
   • Be careful not to damage the oil seal lip.
7. Remove the SST.

   SST 09631-00350 

   Fig 4: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with power steering fluid, and install it to the stopper.
2. Using a wooden block and a hammer, drive in the stopper until it is tightly installed.
   NOTE: Be careful not to damage the O-ring.
   Fig 5: Installing Cylinder End Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, torque the stopper.

   SST 09631-20120 

   Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf) 

   Fig 6: Tightening Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the SST to the unions of the rack housing.

   SST 09631-12071 (09633-00010) 

2. Apply 53.33 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.

Fig 7: Inspecting Air Tightness Of Rack Housing Unions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new oil seal lip with power steering fluid.
2. Using SST, press in the oil seal.

   SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150) 

   NOTE: Make sure that the oil seal is installed facing in the correct direction.
   Fig 8: Installing Power Steering Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Coat a new bearing with molybdenum disulfide lithium base grease.
4. Using SST, press in the bearing.

   SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150) 

   Fig 9: Installing Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a plastic hammer and a sliding handle, lightly tap in a new union seat.
   NOTE: Before installing the union seat, remove dust sticking to the control valve housing.
   Fig 10: Installing Union Seat

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the rings with power steering fluid.
3. Expand 4 new rings with your fingers.
   Fig 11: Expanding Teflon Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the rings to the control valve assembly, and settle them down with your fingers.
5. Carefully slide the tapered end of SST over the rings until the ring fits to the steering rack.

   SST 09631-20081 

   NOTE: Be careful not to overexpand the ring.
   Fig 12: Installing Ring To Control Valve Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Coat the teflon rings with power steering fluid.
7. To prevent oil seat lip damage, wind vinyl tape on the serrated port of the control valve shaft.
8. Push the valve assembly into the control valve housing.
   NOTE: Be careful not to damage the teflon rings and oil seal lip.
   Fig 13: Identifying Vinyl Tape On Control Valve Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
10. Coat a new oil seal lip with power steering fluid.
11. Using SST and a hammer, drive in the oil seal.

    SST 09950-60010 (09951 -00390), 09950-70010 (09951-07100) 

    NOTE: Make sure to install the oil seal facing in the correct direction.
12. Lightly mount the control valve assembly between aluminum plates in a vise.
13. To prevent oil seal lip damage, wind vinyl tape on the pinion part of the control valve shaft.
    Fig 14: Installing Oil Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Using SST, torque the guide nut.

    SST 09631-20060 

    Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

    NOTE: Be careful not to damage the oil seal lip.
    Fig 15: Tightening Guide Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Using a punch and a hammer, stake the nut.
16. Coat a new O-ring with power steering fluid, and install it to the valve housing.
    Fig 16: Staking Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Apply molybdenum disulfide base grease for the needle roller bearing inside the rack housing in the illustrated portion.

    Volume of grease applied: 

    Approximately 2 g (0.07 oz) 

18. Install the control valve assembly with the 2 bolts.

    Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    Fig 17: Identifying Grease Filling Portion

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rack guide and 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. Using a hexagon wrench (24 mm), temporarily install the spring cap.

Fig 18: Installing Spring Cap

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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), tighten the rack guide spring cap.

   Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

3. Return the cap 30°.
   Fig 19: Tightening 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. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring is not functioning.
   Fig 20: Turning Control Valve Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, a torque wrench and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

   SST 09616-00011 

   Torque: Preload in center position (turning) 1.35 to 1.55 N*m (13.77 to 15.81 kgf*cm, 11.94 to 13.71 in.*lbf) 

   Fig 21: Tightening Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Adjustment should be done in the tightening direction of the spring cap.

   HINT:

   Adjust the preload so that the turning torque of the control valve shaft, with the steering rack in the center position, is within the specification.

7. Apply sealant to 2 or 3 threads of the lock nut.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

8. Temporarily install the lock nut.
9. Using a hexagon wrench (24 mm), holding the rack guide spring cap rotating, and using SST, torque the nut.

   SST 09922-10010 

   Torque: 65 N*m (660 kgf*cm, 48 ft.*lbf) for use with SST 

   Fig 22: Tightening Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   HINT:

   Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

10. Recheck the total preload.

    Torque: Preload in center position (turning) 

    1.35 to 1.55 N*m (13.77 to 15.81 kgf*cm, 11.94 to 13.71 in.*lbf) 

    HINT:

    Adjust the preload so that the tuning torque of the control valve shaft, with the steering rack in the center position, is within the specification.

11. Remove the RH and LH rack ends.

Fig 23: Checking Total Preload

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new claw washer, and temporarily tighten the rack end.

   HINT:

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

2. Using SST to hold the steering rack steady, and using another SST, torque the rack end LH.

   SST 09922-10010 

   Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) for use with SST 

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

   HINT:

   Use a torque wrench with a fulcrum length of 380 mm (14.9 in.).

   Fig 24: Tightening Rack End LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST to hold the rack end LH steady, and using another SST, torque the rack end RH.

   SST 09922-10010 

   Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) for use with SST 

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

   HINT:

   Use a torque wrench with a fulcrum length of 380 mm (14.9 in.).

   Fig 25: Tightening Rack End RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a brass bar and a hammer, stake the washer.
   NOTE: Avoid any impact to the rack.
5. Employ the same manner described above to the other side.

1. Install the boot.

Fig 26: Staking Washer

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Using pliers and a screwdriver, install the clamp.

HINT:

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

1. Using pliers, install the clip.

Fig 27: Installing Steering Rack Boot Clamp LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Using SST, check that the rack boot stretches smoothly when the control valve shaft is being rotated.

   SST 09616-00011 

   Fig 28: Inspecting Power Steering Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease in the illustrated portion.
3. Install the dust cover.

Fig 29: Identifying Grease Filling Portion

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, install the 2 turn pressure tubes.

   SST 09023-38201 

   Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf) for use with SST 

   HINT:

   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   • This torque value is effective in case that SST is parallel to a torque wrench.

Fig 30: Installing Turn Pressure Tubes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.

   Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 

HINT:

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