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Reassembly (Tacoma 2WD)

  1. With rack housing mounted vertically in soft-jaw vise, coat NEW seal with power steering fluid, and press into rack housing from end opposite control valve housing portion. See Figure. Ensure oil seal faces in proper direction.
  2. Mount rack housing horizontally in vise. Clean rack teeth of any burrs. Place protective sleeve end piece on steering rack teeth end. Coat protective sleeve with power steering fluid. Install steering rack into rack housing. Remove protective sleeve.
  3. Coat NEW "O" ring with power steering fluid, and install on rack bushing. Tape steering rack end and coat end with power steering fluid. Install rack bushing. Remove tape.
  4. Align hole for wire of cylinder end stopper with slot of rack housing. Use installer tool and turn stopper clockwise 400-500 degrees. See Figure.
  5. Install special connectors onto union fittings of rack housing and attach hand vacuum pump. Apply 15.75" Hg for about 30 seconds. Ensure there is no vacuum leak. If there is, check installation of oil seals at each end of housing. See Figure.
  6. Coat Teflon rings of control valve assembly with power steering fluid. Wrap serrated end of control valve shaft with tape. Push control valve assembly into housing. Press NEW oil seal into place after coating lip with power steering fluid.
  7. Place NEW gasket on rack housing. Position control valve housing. Install and tighten mounting bolt. See TORQUE SPECIFICATIONS . Hold control valve shaft from turning, and install NEW self-locking nut on lower end of shaft. Install dust cover.
  8. Apply thread lock sealant to 2-3 threads of rack housing cap. Install and tighten cap to specification. See TORQUE SPECIFICATIONS . Stake cap in 2 places.
  9. Install rack guide seat to guide. Apply thread lock sealant to 2-3 threads of rack guide spring cap. Install guide, spring, washer and cap. Temporarily tighten cap.
  10. Temporarily install both rack ends. Using 21-mm wrench, tighten rack guide spring cap to 18 ft. lbs. (24 N.m). Loosen cap by 12 degrees. Using torque wrench on top end of control valve stem, turn stem right and left 1-2 times. Loosen rack guide spring cap until rack guide spring is not functioning. Tighten rack guide spring cap until preload is within 7.8-13.0 INCH lbs. (0.9-1.5 N.m), measured with torque wrench on control valve stem. See Figure.
  11. Apply thread lock sealant to rack guide spring cap lock nut. Hold spring cap from rotating, use torque wrench to tighten lock nut to specification. See TORQUE SPECIFICATIONS . Recheck preload.
  12. Remove both rack ends. Install No. 2 rack housing bracket and grommet. Align reference marks. Install and tighten bolt. See TORQUE SPECIFICATIONS .
  13. Install NEW claw washers on each end of rack. Align claws with grooves in rack. Install rack ends. Hold rack from turning, and tighten rack ends to 44 ft. lbs. (60 N.m). Stake claw washers.
  14. Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots, clamps and clips. Pinch clamp until there is .08" (2.0 mm) or less clearance between clamp ends.
  15. Screw tie rod end lock nut onto tie rod until reference marks are aligned. Install left and right tie rod ends. After adjusting toe-in, tighten lock nuts to specification. See TORQUE SPECIFICATIONS .
  16. Install 2 turn pressure tubes. Use NEW "O" rings coated with power steering fluid. Tighten fittings to specification. See TORQUE SPECIFICATIONS .
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