FixVault
Home › Toyota › 2002 › Sienna LE › Repair and Diagnosis › Steering › Power Steering › Steering System › Power Steering Gear › Reassembly

Power Steering Gear: Reassembly

NOTE: When using a vise, do not overtighten it.
  1. Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease. See  COMPONENTS  . 
  2. Install oil seal  :
    1. Coat a new oil seal lip with power steering fluid.
      2. NOTE:
      • Make sure that the oil seal is installed facing in the correct direction.
      • Take care that the oil seal does not get reversed as you install it.
      Fig 1: Pressing Oil Seal Into Steering Rack
      G01050884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal.

      SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

  3. Install steering rack  :
      NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.
      Fig 2: Using Special Service Tool To Install Steering Rack Into Housing
      G01050885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST to the steering rack.

      SST 09631-33010

    2. Coat the SST with power steering fluid.
      3. CAUTION: Be careful not to damage the oil seal lip.
    3. Install the rack into the rack housing.
    4. Remove SST.

      SST 09631-33010

  4. 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.
      Fig 3: Using Vinyl Tape To Prevent Oil Seal Damage
      G01050886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. NOTE:
      • Make sure that the bushing is installed facing in the correct direction.
      • Be careful not to damage the oil seal lip.
    3. Install the bushing.
  5. Install cylinder end stopper  :
    1. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
      Fig 4: Installing Cylinder End Stopper & Wire
      G01050887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new wire into the cylinder end stopper.
    3. Using SST, turn the cylinder end stopper clockwise 450 +/- 50°.

      SST 09631-10021

  6. Air tightness test  :
    1. Install SST to the rack housing.

      SST 09631-12071

    2. Apply 53 kPa (400 mm Hg, 15.75 in. Hg) of vacuum for about 30 seconds.
      Fig 5: Using Vacuum Pump To Check For Internal Leaks
      G01050888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Check that there is no change in the vacuum.

      If there is change in the vacuum, check the installation of the oil seals.

  7. Install rack housing no. 2 bracket and grommet  :
      NOTE: Align the projection of the rack housing No. 2 grommet with the hole of the rack housing No. 2 bracket.
      Fig 6: Aligning Rack Housing Grommet Projection With Rack Housing Hole
      G01050889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the rack housing No. 2 grommet to the rack housing No. 2 bracket.
    2. Align the matchmarks on the rack housing No. 2 bracket and rack housing.
    3. Place the rack housing No. 2 bracket in a vise and tighten the vise to fasten the clamp.
      Fig 7: Using Vise To Fasten Clamp
      G01050890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install control valve assembly  :
    1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
    2. Coat the teflon rings with power steering fluid.
      3. CAUTION: Be careful not to damage the teflon rings and oil seal.
      Fig 8: Using Vinyl Tape To Prevent Damage During Control Valve Assembly Installation
      G01050891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the control valve assembly into the control valve housing.
  9. Install oil seal  :
    1. Coat a new oil seal lip with power steering fluid.
      2. NOTE: Make sure that the oil seal is installed facing in the correct direction.
      Fig 9: Installing Control Valve Assembly Oil Seal
      G01050892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, press in the oil seal.

      SST 09612-22011

  10. 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 and rack housing.
    3. Install the 2 bolts.

      Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 

  11. Install self-locking nut  .
    Fig 10: Identifying Self-Locking Nut
    G01050893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Using SST, stop the control valve shaft rotating and install a new self-locking nut.

    SST 09616-00011

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

  12. Install dust cover  .
  13. 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. Install the rack housing cap.

      Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) 

    3. Using a punch and a hammer, stake the 2 parts of the rack housing cap.
      Fig 11: Staking Rack Housing Cap
      G01050894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Install rack guide sub-assembly, rack guide spring and rack guide spring cap  :
    1. Install the rack guide sub-assembly 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.
  15. 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 (21 mm), torque the rack guide spring cap.
      Fig 12: Using SST To Turn Rack Guide Spring Cap
      G01050895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Using a hexagon wrench (21 mm), return the cap 12°.
    4. Using SST, turn the control valve shaft right and left 1 or 2 times.
      Fig 13: Using SST To Turn Control Valve Shaft
      G01050896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09616-00011

    5. Using a hexagon wrench (21 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
    6. Using SST, a torque wrench and a hexagon wrench (21 mm), tighten the rack guide spring cap until the preload is within specification.
      Fig 14: Setting Preload On Rack Guide Spring Cap
      G01050897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09616-00011

      Preload (turning): 

      0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in.lbf)  .

  16. Install rack guide spring cap lock nut  :
    1. Apply sealant to 2 or 3 threads of the rock guide spring cap lock nut.

      Sealant: 

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

    2. Temporarily install the rack guide spring cap lock nut.
    3. Using a hexagon wrench (21 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
      Fig 15: Tightening Rack Guide Spring Cap Lock Nut
      G01050898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09922-10010

      Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction shown in Fig 15.

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

    4. Recheck the total preload.

      Preload (turning): 

      0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in.lbf)  .

    5. Remove the RH and LH rack ends.
  17. Install RH and LH claw washers and rack ends  :
      NOTE: Align the claws of the claw washers with the steering rack grooves.
      Fig 16: Installing Claw Washer
      G01050899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new claw washer, and temporarily install the rack ends.
    2. Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end.

      SST 09922-10010

      Torque: 60 N.m (610 kgf.cm, 44 ft.lbf) 

      NOTE: Use SST 09922-10010 in the direction shown in Fig 17.

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

      Fig 17: Tightening Rack End
      G01050900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. CAUTION: Avoid any impact on the steering rack.
      Fig 18: Staking Claw Washer
      G01050901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, stake the claw washer.
    4. Employ the same manner described above to the other side.
  18. Install RH and LH rack boots, clamps and clips  :
      CAUTION: If the hole is clogged, the pressure inside the rack boot will change after it is assembled and the steering wheel is turned.
      Fig 19: Locating Steering Rack Hole
      G01050902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Ensure that the steering rack hole is not clogged with grease.
    2. Install the rack boot, clip and a new clamp.
      NOTE: Be careful not to damage or twist the rack boot.
    3. Using SST, tighten the clamp as shown in Fig 20.

      SST 09521-24010

    4. Employ the same manner described above to the other side.
      Fig 20: Using Special Service Tool To Tighten Clamp
      G01050903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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.
      Fig 21: Matchmarking Tie Rod & Rack End
      G01050904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. After adjusting toe-in, torque the lock nut. See TORQUE SPECIFICATIONS .

      Torque: 74 N.m (750 kgf.cm, 54 ft.lbf) 

    3. Employ the same manner described above to the other side.
  20. Install 2 turn pressure tubes  :
    1. Coat 4 new "O" rings with power steering fluid and install them to the 2 turn.
      2. 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.
      Fig 22: Using Special Service Tool To Install Turn Pressure Tubes
      G01050905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the pressure tubes.

      SST 09023-38200

      Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)  .

About FixVault