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Reassembly (ES300 & RX300)

  1. Lubricate all parts with power steering fluid. Using Oil Seal Driver (09950-60010), install NEW oil seal in rack housing. Coat with oil and install Rack Guide (09631-33010) onto rack. Install rack into rack housing. Remove rack guide. Repeat procedure to install seal and rack on opposite end of rack housing. DO NOT tilt or damage seal.
  2. Coat NEW "O" rings with oil and install to rack housing bushings. Install bushings into rack housing.
  3. Align installation hole for wire of stopper with slot in rack housing. Install NEW wire into stopper. Using Socket Wrench (09631-10021), rotate stopper clockwise until end of stopper retainer wire disappears. Connect Steering Rack Oil Seal Tester (09631-12071) to pressure line fittings. Apply 16 in. Hg vacuum to rack assembly. If vacuum does not hold for 30 seconds, check installation of oil seals.
  4. Install rack housing grommets into brackets. Align reference marks on rack housing brackets and rack housing, place brackets in vise and tighten vise to fasten clamps. Coat Teflon rings with PS fluid and install control valve assembly into valve housing. Using Seal Driver (09612-22011), press NEW seal into control valve housing. Place NEW gasket on rack housing. Align reference marks on valve housing and rack housing and install control valve assembly. Install self-locking nut and dust cover.
  5. Apply Loctite Sealant to rack housing cap. Install rack housing cap and tighten to 43 ft. lbs. (58 N.m). Stake housing cap in 2 places. Install rack guide sub-assembly, rack guide spring and rack guide spring cap. Using torque wrench and Socket (09631-10021), tighten spring cap to 18 ft. lbs. (24 N.m). Loosen spring cap 12 degrees counterclockwise. Using an INCH-lb. torque wrench and Socket (09616-00010), rotate control valve shaft left and right 1 to 2 times. Loosen spring cap until spring is not compressed.
  6. With INCH-lb. torque wrench attached to control valve shaft, tighten rack guide spring cap until control valve shaft rotating torque is 7-12 INCH lbs. (.8-1.4 N.m). Apply sealant to 2 or 3 threads rack guide spring cap lock nut. While holding spring cap from turning, tighten spring cap lock nut to 37 ft. lbs. (50 N.m). Recheck control valve turning torque, and readjust if necessary.
  7. Install rack ends and NEW claw washers. Align claw washer tangs with steering rack grooves. Using a 24 mm end wrench to hold steering rack steady, and Spanner Wrench (09922-10010), tighten rack ends to 45 ft. lbs. (61 N.m). Using a brass punch and hammer, stake claw washers. DO NOT damage rack. Install rack boots, clamps and clips. Install outer tie-rod ends and lock nuts, aligning reference marks. After adjusting toe-in, tighten lock nuts to specification. Install 2 turn pressure tubes with NEW "O" rings.
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