Rack & Pinion Power Steering Gear ASSY: Overhaul

SST 09950-50013 (09951-05010, 09953-05020, 09954-05021,)

1. Remove the cotter pin and nut.
2. Using SST, remove the tie rod assy LH from the steering knuckle.

   SST 09628-62011

   Fig 1: Removing Tie Rod Assy LH From Steering Knuckle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09628-62011

HINT:

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

1. Loosen the bolt and remove the clamp from the steering column hole cover No.1.
2. Disconnect the steering column hole cover No.2 from the steering column hole cover No.1.
3. Loosen the bolt.
Fig 2: Loosening Bolts For Steering Column Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place matchmarks on the steering intermediate shaft sub-assy and rack & pinion power steering gear assy.
5. Remove the bolt and disconnect the steering intermediate shaft sub-assy.
   Fig 3: Placing Matchmarks On Steering Intermediate Shaft Sub-Assy And Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the nut and disconnect the front stabilizer link assy LH from the shock absorber assy front LH.
   Fig 4: Removing Nut And Disconnecting Front Stabilizer Link Assy LH From Shock Absorber Assy Front LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

HINT:

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

1. Remove the 2 bolts and disconnect the front stabilizer bracket No.1 LH.
   Fig 5: Removing Front Stabilizer Bracket No.1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Using SST, disconnect the return tube assy from the rack & pinion power steering gear assy.

   SST 09023-12700

   Fig 6: Disconnecting Return Tube Assy From Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, disconnect the pressure feed tube assy from the rack & pinion power steering gear assy.

   SST 09023-12700

   Fig 7: Disconnecting Pressure Feed Tube Assy From Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the nut and disconnect the return tube assy clamp.
   Fig 8: Removing Nut & Disconnecting Return Tube Assy Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and disconnect the tube clamp.
   Fig 9: Removing Bolt And Disconnecting Tube Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts, 2 nuts and rack & pinion power steering gear assy.
   Fig 10: Removing Bolts, Nuts And Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the power steering rack housing heat insulator.

1. Using SST, remove the steering left turn pressure tube.

   SST 09023-38200

2. Remove the 2 O-rings from the steering left turn pressure tube.
   Fig 11: Removing Steering Left Turn Pressure Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the steering right turn pressure tube.

   SST 09023-38200

2. Remove the 2 O-rings from the steering right turn pressure tube.

1. Using SST, secure the rack & pinion power steering gear assy.

   SST 09612-00012

   Fig 12: Using SST To Secure Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the SST before use.

1. Place matchmarks on the tie rod assy LH and steering rack end sub-assy.
2. Loosen the lock nut, and remove the tie rod assy LH and lock nut.
   Fig 13: Placing Matchmarks On Tie Rod Assy LH And Steering Rack End Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Secure the tie rod assy LH in a vise.
2. Install the nut to the stud bolt.
3. Flip the ball joint stud back and forth 5 times.
4. Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading of the 5th turn.

   Turning torque: 

   0.83 - 3.43 N.m (8.5 - 35.0 kgf.cm, 7.3 - 30.4 in .lbf) 

Fig 14: Inspecting Tie Rod Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Remove the 2 steering rack boot clips.

1. Using pliers, remove the steering rack boot NO.2 clamp.
   NOTE: Be careful not to damage the steering rack boot No.2.

HINT:

Remove the steering rack boot No.1 clamp by the same procedures with the steering rack boot No.2 clamp.

1. Remove the steering rack boot No.2

HINT:

Remove the steering rack boot No.1 by the same procedures with the steering rack boot NO.2.

1. Using a screwdriver and a hammer, unstake the claw washer.
   Fig 15: Unstaking Claw Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Avoid any impact to the power steering rack.
2. Using 2 SSTs, remove the 2 steering rack ends sub-assy and 2 claw washers.

   SST 09922-10010

   Fig 16: Removing Steering Rack Ends Sub-Assy And Claw Washers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Use SST 09922-10010 in the direction shown in Fig 16.
   • Securely hold the steering rack end sub-assy with a SST.

1. Using SST, remove the rack guide spring cap nut.

   SST 09922-10010

   Fig 17: Removing Rack Guide Spring Cap Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Use SST 09922-10010 in the direction shown in Fig 17.
2. Using SST, remove the rack guide spring cap.

   SST 09631-10021

Fig 18: Removing Rack Guide Spring Cap
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the compression spring and rack guide.

1. Using a socket wrench (27 mm), remove the rack housing cap.
   Fig 19: Removing Rack Housing Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, hold the control valve and remove the nut.

   SST 09616-00011

   Fig 20: Holding Control Valve And Removing Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Wind vinyl tape around the serrated part of the control valve.
4. Remove the dust cover from the control valve housing.
   Fig 21: Winding Vinyl Tape Around Serrated Part Of Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 bolts and control valve housing.
6. Remove the gasket.
   Fig 22: Removing Bolts And Control Valve Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
8. Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
9. Remove the oil seal from the control valve.
   Fig 23: Removing Control Valve With Oil Seal From Control Valve Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a screwdriver, remove the 4 control valve rings.
    NOTE: Be careful not to damage the grooves for the control valve ring.
    Fig 24: Removing Control Valve Rings

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the control valve upper bearing and power steering control valve upper oil seal from the control valve housing.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)

   Fig 25: Removing Power Steering Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
2. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
   Fig 26: Removing Cylinder End Stopper

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the power steering rack and power steering rack bush.

1. Remove the power steering rack bush from the power steering rack.
2. Using SST, remove the rack bush oil seal.

   SST 09527-21011, 09612-24014 (09613-22011)

   Fig 27: Removing Power Steering Rack Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the O-ring from the power steering rack bush.

1. Using a dial indicator, check the power steering rack for runout and for teeth wear and damage.

   Maximum runout: 0.3 mm (0.012 in.) 

2. Check the back surface for wear and damage.
   Fig 28: Inspecting Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press, remove the power steering cylinder tube oil seal.

   SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)

   Fig 29: Removing Power Steering Cylinder Tube Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the rack steering piston ring and O-ring.
   Fig 30: Removing Rack Steering Piston Ring And O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the grooves for rack steering piston ring.

1. Coat a new O-ring with power steering fluid and install it to the power steering rack.
2. Expand a new rack steering piston ring with your fingers.
   Fig 31: Expanding New Rack Steering Piston Ring With Fingers

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to over expand the rack steering piston ring.
3. Coat the new rack steering piston ring with power steering fluid.
4. Install the rack steering piston ring to the power steering rack, and settle it down with your fingers.
   Fig 32: Installing Rack Steering Piston Ring To Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new power steering cylinder tube oil seal lip with power steering fluid.

   SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360)

2. Using SST and a press, install the power steering cylinder tube oil seal.
   Fig 33: Installing Power Steering Cylinder Tube Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
   • Take care so that the power steering cylinder tube oil seal will not be reversed as you install it.

1. Install SST to the power steering rack.

   SST 09631-33010

   Fig 34: Installing SST To Power Steering Rack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

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

2. Coat the SST with power steering fluid.
3. Install the power steering rack into the rack housing.
4. Remove the SST.

1. Using SST and a press, install the rack bush oil seal to the power steering rack bush.

   SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

   Fig 35: Installing Power Steering Rack Bush Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the rack bush oil seal is installed facing in the correct direction.
2. Coat a new O-ring with power steering fluid and install it to the power steering rack bush.
3. To prevent rack bush oil seal lip damage, wind vinyl tape around the power steering rack end, and apply power steering fluid.
4. Install the power steering rack bush to the power steering rack.
   Fig 36: Winding Vinyl Tape Around Power Steering Rack End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
2. Install a new wire into the cylinder end stopper.
3. Using a screwdriver, turn the cylinder end stopper clockwise by 450 +/- 50+/-.
   Fig 37: Turning Cylinder End Stopper Clockwise

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install SST to the rack housing.

   SST 09631-12071 (09633-00010)

   Fig 38: Installing SST To Rack Housing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for about 30 seconds.
3. Check that there is no change in the vacuum.

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

1. Coat a control valve upper bearing and a new power steering control valve upper oil seal with power steering fluid.
2. Using SST and a press, install the power steering control valve upper oil seal.

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

   Fig 39: Installing Power Steering Control Valve Upper Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST and a press, install the control valve upper bearing.

   SST 09950-70010 (09951-07150), 09950-60010 (09951-00180, 09952-06010, 09951-00340)

   Fig 40: Installing Control Valve Upper Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Expand 4 new control valve rings with your fingers.
   NOTE: Be careful not to over expand the control valve ring.
Fig 41: Expanding New Control Valve Rings With Fingers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat the 4 control valve rings with power steering fluid.
3. Install the 4 control valve rings to the control valve, and settle them down with your fingers.
4. Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve.

   SST 09631-20081

   Fig 42: Installing Control Valve Rings To Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Be careful not to damage the control valve rings.
5. To prevent power steering control valve upper oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
   Fig 43: Winding Vinyl Tape Around Serrated Part Of Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Coat the power steering control valve upper oil seal lip with power steering fluid.
7. Install the control valve to the control valve housing.
   NOTE: Be careful not to damage the control valve ring and power steering control valve upper oil seal lip.
8. Coat a new oil seal lip with power steering fluid.
9. Using SST and a press, install the oil seal.

   SST 09612-22011

   Fig 44: Installing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Make sure that the oil seal is installed facing in the correct direction.
10. Apply grease to the needle bearing.
11. Install a new gasket to the control valve housing.
12. Wind vinyl tape around the serration part of the control valve.
13. Install the control valve housing to the rack housing with the 2 bolts.

    Torque: 21 N.m (214 kgf.cm, 15 ft.lbf) 

Fig 45: Installing Control Valve Housing To Rack Housing With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Using SST, stop the control valve rotation and install a new lock nut.

    Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

    SST 09616-00011

    Fig 46: Installing New Lock Nut

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Apply sealant to 2 or 3 threads of the rack housing cap.

    Sealant: 

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

16. Using a socket wrench (27 mm), install the rack housing cap.

    Torque: 58.5 N.m (597 kgf.cm, 43 ft.lbf) 

    Fig 47: Installing Rack Housing Cap

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. Using a punch and a hammer, stake the rack housing cap and rack housing.
    Fig 48: Staking Rack Housing Cap And Rack Housing

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply molybdenum disulfide lithium base grease to the rack guide.
2. Install the rack guide.
3. Install the compression spring.
4. 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 

5. Temporarily install the rack guide spring cap.

1. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack ends sub-assy.
2. Using SST, torque the rack guide spring cap.

   SST 09631-10021

   Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

   Fig 49: Installing Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, loosen the rack guide spring cap.

   SST 09631-10021

   Fig 50: Loosening Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve to the right and left 1 or 2 times.

   SST 09616-0011

   Fig 51: Turning Control Valve To Right And Left 1 Or 2 Times

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using SST, loosen the rack guide spring cap until the compression spring is not functioning.

   SST 09631-10021

6. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.

   SST 09616-00011, 09631-10021

   Fig 52: Tightening Rack Guide Spring Cap

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Preload (turning): 

   1.2 - 1.5 N.m (12.2 - 15.3 kgf.cm, 10.6 - 13.3 in .lbf) 

7. Apply sealant to 2 or 3 threads of the rack guide spring cap nut.

   Sealant: 

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

8. Temporarily install the rack guide spring cap nut.
9. Using SST, and hold the rack guide spring cap and using another SST, tighten the rack guide spring cap nut.

   SST 09616-00011, 09922-10010

   Fig 53: Tightening Rack Guide Spring Cap Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 48 N.m (489 kgf.cm, 35 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in Fig 53.

   HINT:

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

10. Precheck the total preload.

    Preload (turning): 

    1.2 - 1.5 N.m (12.2 - 15.3 kgf.cm, 10.6 - 13.3 in.lbf) 

11. Remove the RH and LH steering rack ends sub-assy.
12. Apply MP grease into the control valve, as shown in Fig 54.
    Fig 54: Applying MP Grease Into Control Valve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. Wind vinyl tape around the serration part of the control valve.
    Fig 55: Winding Vinyl Tape Around Serration Part Of Control Valve

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. Install the dust cover to the control valve housing.

1. Install a new 2 claw washers, and temporarily install the 2 steering rack ends sub-assy.
   Fig 56: Installing Steering Rack End Sub-Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

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

2. Using 2 SSTs, install the 2 steering rack ends sub-assy.

   SST 09922-10010

   Torque: 58.5 N.m (597 kgf.cm, 43 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in Fig 56.

   HINT:

   • Using SST, hold the power steering rack and install the steering rack end sub-assy.
   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
3. Using a brass bar and a hammer, stake the claw washer.
   Fig 57: Staking Claw Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Avoid any impact to the power steering rack.

1. Ensure that the steering rack end sub-assy hole is not clogged with grease.
   Fig 58: Inspecting Steering Rack End Sub-Assy Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.

1. Install the steering rack boot No.2.

HINT:

Remove the steering rack boot No.1 by the same procedures with steering rack boot NO.2.

1. Using SST, tighten the steering rack boot No.2 clamp, as shown in Fig 59.

   SST 09521-24010

   Fig 59: Tightening Steering Rack Boot No. 2 Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Clearance: 3.0 mm (0.118 in.) or less 

   NOTE: Be careful not to damage the steering rack boot No.2.

SST 09521-24010

HINT:

Install the steering rack boot No.1 clamp by the same procedures with steering rack boot No.2 clamp.

1. Using pliers, install the 2 steering rack boot clips.

1. Screw the lock nut and tie rod assy LH onto the steering rack end sub-assy until the matchmarks are aligned.

   HINT:

   After adjusting toe-in, torque the lock nut.

HINT:

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

1. Coat 2 new O-rings with power steering fluid and install them to the steering left turn pressure tube.
2. Using SST, install the steering left turn pressure tube to the rack & pinion power steering gear assy.

   SST 09023-38200

   Torque: 11.5 N.m (117 kgf.cm, 8 ft.lbf) 

   Fig 60: Installing Steering Left Turn Pressure Tube To Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Use a torque wrench with a fulcrum length of 345 mm (9.84 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.

1. Coat 2 new O-rings with power steering fluid and install them to the steering right turn pressure tube.
2. Using SST, install the steering right turn pressure tube to the rack & pinion power steering gear assy.

   Torque: 11.5 N.m (11 kgf.cm, 8 ft.lbf) 

   Fig 61: Installing Steering Right Turn Pressure Tube To Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Use a torque wrench with a fulcrum length of 345 mm (11.81 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.

1. Install the power steering rack housing heat insulator.

   HINT:

   Install nut when installing the return clamp.

1. Install the rack & pinion power steering gear assy with the 2 bolts and 2 nuts.
   Fig 62: Installing Rack & Pinion Power Steering Gear Assy With Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 70 N.m (714 kgf.cm, 52 ft.lbf) 

2. Connect the tube clamp with the bolt.
   Fig 63: Connecting Tube Clamp With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

1. Using SST, connect the pressure feed tube assy to the rack & pinion power steering gear assy.

   SST 09023-12700

   Torque: 22.5 N.m (229 kgf.cm, 17 ft.lbf) 

   Fig 64: Connecting Pressure Feed Tube Assy To Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.
2. Using SST, connect the return tube assy to the rack & pinion power steering gear assy.

   SST 09023-12700

   Torque: 22.5 N.m (229 kgf.cm, 17 ft.lbf) 

   Fig 65: Connecting Return Tube Assy To Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
   • This torque value is effective in the case that SST is parallel to a torque wrench.
3. Install the return tube assy clamp with the nut.

   Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf) 

   Fig 66: Installing Return Tube Assy Clamp With Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the front stabilizer bracket No. 1 LH with the 2 bolts.

   Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

   Fig 67: Installing Front Stabilizer Bracket No.1 LH With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

1. Connect the front stabilizer link assy LH to the shock absorber assy front LH with the nut.

   Torque: 74 N.m (755 kgf.cm, 55 ft.lbf) 

   Fig 68: Connecting Front Stabilizer Link Assy LH To Shock Absorber Assy Front LH With Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

HINT:

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

1. Align the matchmarks on the steering intermediate shaft sub-assy and rack & pinion power steering gear assy.
   Fig 69: Aligning Matchmarks On Steering Intermediate Shaft Sub-Assy And Rack & Pinion Power Steering Gear Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bolt.

   Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf) 

3. Tighten the bolt.

   Torque: 35.3 N.m (360 kgf.cm, 26 ft.lbf) 

4. Install the steering column hole cover No.2 to the steering hole cover No.1.
5. Connect the clamp to the steering column hole cover No.1 and tighten the bolt.

1. Connect the tie rod assy LH with the nut.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

2. Install a new cotter pin.
   NOTE: If the holes for a new cotter pin are not aligned, tighten the nut further up 60°.

HINT:

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

Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf) 

(See  OVERHAUL  ) 

(See  OVERHAUL  )