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Steering Gear: Reassembly

CAUTION: When using a vise, do not overtighten it.
  1. Coat with power steering fluid or molybdenum disulfide lithium base grease. See Figure and Figure .
    2. CAUTION: Make sure you 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 New Oil Seal
    G00133004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Coat a new oil seal lip with power steering fluid. Using the Replacer Set: Replacer 24, Replacer 43 and Adapter and the Handle Set: Handle 360 (SST 09950-60010, 09951-00240, 09951-00430, 09952-06010, 09950-70010, 09951-07360), press the oil seal. See Fig 1.
    3. CAUTION: Be careful not to damage the oil seal lip.
    Fig 2: Installing Steering Rack
    G00131939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install Steering Rack Cover I (SST 09631-33010) to the rack. See Fig 2. If necessary, scrape the burrs off the rack teeth end and burnish. Coat the Steering Rack Cover I with power steering fluid. Install the rack into the rack housing. Remove the Steering Rack Cover I.
    4. CAUTION: Make sure you install the bushing facing the correct direction and be careful not to damage the oil seal lip.
    Fig 3: Installing Bushing
    G00131940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Coat a new O-ring with power steering fluid. Install the O-ring to the bushing. To prevent oil seal damage, wind vinyl tape on the steering rack end, and apply power steering fluid. See Fig 3. Install the bushing.
  5. Install the cylinder end stopper. Align the installation hole for the wire of the stopper with the slot of the rack housing. Install a new wire into the stopper. Using the Cylinder End Stopper Nut Wrench (SST 09631-16010), turn the stopper clockwise 400-500°. See Fig 4.
    Fig 4: Installing Cylinder End Stopper
    G00131941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install the Steering Rack Oil Seal Test Tool (SST 09631-12071) to the rack housing. See Fig 5. Apply 15.75 in. Hg (53 kPa, 400 mm Hg) of vacuum for about 30 seconds. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals.
    Fig 5: Inspecting Air Tightness
    G00131942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install rack housing No. 2 bracket and grommet. Install the grommet to the bracket. Align the projection of the grommet with the hole of the bracket. See Fig 6. Align the matchmarks on the bracket and rack housing. Place the bracket in a vise and tighten the vise to fasten the clamp. See Fig 7.
    Fig 6: Installing Rack Housing No. 2 Bracket & Grommet
    G00131943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Fastening Clamp
    G00131944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. CAUTION: Be careful not to damage the teflon rings and oil seal.
    Fig 8: Installing Control Valve Assembly
    G00131945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install the control valve assembly. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. See Fig 8. Coat the teflon rings with power steering fluid. Install the valve assembly into the valve housing.
    9. CAUTION: Make sure you install the oil seal facing the correct direction.
    Fig 9: Installing New Oil Seal
    G00133005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Install a new oil seal. Coat a new oil seal with power steering fluid. Using the Tilt Handle Bearing Replacer (SST 09612-22011), press in the oil seal. See Fig 9.
  10. Install the control valve housing with control valve assembly. Place a new gasket on the rack housing. Align the matchmarks on the valve housing and rack housing. Tighten the 2 bolts to 13 ft. lbs. (18 N.m).
  11. Using the Steering Worm Bearing Adjusting Socket (SST 09616-00010) to stop the control valve shaft rotating, tighten the nut to 18 ft. lbs. (25 N.m). See Figure.
  12. Install the dust cover.
  13. Install the rack housing cap. Apply sealant to 2-3 threads of the cap. Use sealant Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent. Tighten the cap to 43 ft. lbs. (59 N.m). Using a punch and hammer, stake the 2 parts of the cap. See Fig 10.
    Fig 10: Installing Rack Housing Cap
    G00131947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Install the rack guide seat, rack guide, rack guide spring and rack guide spring cap. Install the seat to the guide. Apply sealant to 2-3 threads of the cap. Use sealant Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent. Temporarily install the cap.
  15. Adjust total preload. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the right hand and left hand rack ends. Using the Rack Stopper Wrench (SST 09631-10021), tighten the rack guide spring cap to 18 ft. lbs. (25 N.m). See Fig 11. Using the Rack Stopper Wrench (SST 09631-10021), return the cap 12°. See Fig 12.
    Fig 11: Torquing Rack Guide Spring Cap
    G00133006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 12: Returning Cap 12°
    G00133007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Using the Steering Worm Bearing Adjusting Socket (SST 09616-00010), turn the control valve shaft right and left 1-2 times. See Fig 13. Using the Rack Stopper Wrench (SST 09631-10021), loosen the cap until the rack guide spring is not functioning. Using the Steering Worm Bearing Adjusting Socket, Rack Stopper Wrench (SST 09616-00010, 09631-10021) and a torque wrench, tighten the cap until the preload is within specification. See Fig 14 and PRELOAD  .
    Fig 13: Turning Control Valve Shaft
    G00133008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 14: Tightening Rack Guide Spring Cap
    G00133009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    17. NOTE: Use a torque wrench with a fulcrum length of 13.58" (345 mm). Use the Variable Open Wrench in the direction shown. See Fig 15.
    Fig 15: Installing Rack Guide Spring Cap Lock Nut
    G00133010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Install the rack guide spring cap lock nut. Apply sealant to 2-3 threads of the nut. Use sealant Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent. Using the Rack Stopper Wrench and the Variable Open Wrench (SST 09631-10021, 09922-10010), tighten the nut to 37 ft. lbs. (50 N.m). Recheck the total preload. See RACK PRELOAD . Remove the right hand and left hand rack ends.
    RACK PRELOAD

    Measurement Turning Preload
    INCH Lbs. 6.9-12.2
    Kgs. Cm 8-14
    N.m 0.8-1.4
    18. NOTE: Use a torque wrench with a fulcrum length of 13.58" (345 mm). Use the Variable Open Wrench in the direction shown. See Fig 17.
    Fig 16: Installing Claw Washers
    G00131954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 17: Installing Rack Ends
    G00133011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 18: Staking Claw Washer
    G00131956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Install right hand and left hand claw washers and rack ends. Install a new claw washer, and temporarily install the rack end. See Fig 16. Align the claws of the washer with the steering rack grooves. Using a 24 mm spanner to hold the steering rack steady, and using the Variable Open Wrench (SST 09922-10010), tighten the rack end to 44 ft. lbs. (60 N.m). See Fig 17. Using a brass bar and hammer, stake the washer while avoiding any impact to the rack. See Fig 18.
    19. CAUTION: Be careful not to damage or twist the boot.
    Fig 19: Ensuring Steering Rack Hole Is Unclogged
    G00131957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 20: Tightening Boot Clamp
    G00133012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Install right hand and left hand rack boots, clamps and clips. Ensure that the steering rack hole is not clogged with grease. See Fig 19. If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel turned. Install the boot. Using the Drive Shaft Boot Clamping Tool (SST 09521-24010), tighten the clamp. See Fig 20.
  20. Install right hand and left hand tie rod ends and lock nuts. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
    21. NOTE: Use a wrench with a fulcrum length of 9.84" (250 mm).
  21. Install 2 turn pressure tubes. Coat 2 new O-rings with power steering fluid. Install the 2 O-rings to the tube. Using the Power Steering Hose Nut Wrench (SST 09633-00020), install the tube with a torque of 89 INCH lbs. (10 N.m). See Fig 21. Ensure SST is parallel to torque wrench.
Fig 21: Tightening Pressure Tube Flare Nuts
G00133013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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