Power Steering Gear: Reassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: When using a vise, do not overtighten it.

COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
INSTALL POWER STEERING GEAR HOUSING SUBASSEMBLY
1. Install SST to the rack.
  SST 09631-00350
  
  HINT:
  
  If necessary, scrape the burrs off the rack teeth end and burnish.
2. Coat SST with power steering fluid.
3. Install the rack into the rack housing.
4. Remove the SST.
  
  Fig 1: Installing SST To Rack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER STEERING GEAR HOUSING OIL SEAL
1. Install SST to the steering rack opposite end.
  SST 09631-00350
2. Coat SST with power steering fluid.
3. Coat a new oil seal lip with power steering fluid.
4. Install the oil seal by pushing it onto the SST without tilting.
  
  Fig 2: Installing SST To Steering Rack Opposite End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure to install the oil seal facing the correct direction.
5. Remove the SST.
INSTALL SPACER AND CYLINDER END STOPPER
1. Install the spacer.
2. Coat a new O-ring with power steering fluid, and install it to the stopper.
3. Using a wooden block and hammer, drive in the stopper until it is tightly installed.
  NOTE: Be careful not to damage the O-ring.
  
  Fig 3: Driving In Stopper Using Wooden Block & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, torque the stopper.
  SST 09922-10010
  
  Torque: 110 N*m (1,122 kgf*cm, 81 ft.*lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 380 mm (14.97 in.).
  
  Fig 4: Measuring Fulcrum Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
AIR TIGHTNESS TEST
1. Install SST to the unions of the rack housing.
  SST 09631-12071
2. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
3. 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: Installing SST To Unions Of Rack Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CONTROL VALVE ASSEMBLY
1. Coat the Teflon rings with power steering fluid.
2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
3. Push the valve assembly into the control valve housing.
  NOTE: Be careful not to damage the Teflon rings and oil seal lip.
  
  Fig 6: Winding Vinyl Tape On Serrated Part Of Control Valve Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
5. Using SST, torque the nut.
  SST 09631-20060
  
  Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
  
  NOTE: Be careful not to damage the oil seal lip.
  
  Fig 7: Measuring Turning Torque Of Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a punch, stake the nut.
INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
1. Coat a new O-ring with power steering fluid, and install it to the valve housing.
2. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing.
3. Torque the 2 bolts.
  Torque: 18 N*m (180 kgf*cm, 13 ft.*lbf)
  
  Fig 8: Staking Nut Using Punch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER STEERING GEAR HOUSING OIL SEAL
INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
1. Apply sealant to 2 or 3 threads of the cap.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
2. Temporarily install the cap.
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. Torque the rack guide spring cap.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
3. Return the cap 19°.
  
  Fig 9: Tightening Torque Rack Guide Spring Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, turn the control valve shaft right and left 1 or 2 times.
  SST 09616-00011
5. Loosen the cap until the rack guide spring is not functioning.
  
  Fig 10: Turning Control Valve Shaft Right & Left Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST and a torque wrench, tighten the cap until the preload is within specification.
  SST 09616-00011
  
  Preload (turning):
  
  Center area:
  
  1.8 to 2.2 (18.4 to 22.4 kgf*cm, 16.0 to 19.5 in.*lbf)
  
  End area:
  
  1.3 to 1.7 (13.3 to 17.3 kgf*cm, 11.5 to 15.0 in.*lbf)
  
  Fig 11: Tightening Cap Using SST & Torque Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RACK GUIDE SPRING CAP LOCK NUT
1. Apply sealant to 2 or 3 threads of the nut.
  Sealant:
  
  Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
2. Holding the rack guide spring cap rotating, and using SST, torque the nut.
  SST 09922-10010
  
  Torque: 52 N*m (520 kgf*cm, 38 ft.*lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown.
  
  Fig 12: Tightening Nut Using Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 345 mm (14.97 in.).
3. Recheck the total preload.
  Standard preload (turning):
  
  Center area:
  
  1.8 to 2.2 (18.4 to 22.4 kgf*cm, 16.0 to 19.5 in.*lbf)
  
  End area:
  
  1.3 to 1.7 (13.3 to 17.3 kgf*cm, 11.5 to 15.0 in.*lbf)
4. Remove the RH and LH rack ends.
INSTALL CLAW WASHER AND RACK END
1. Install a new washer, and temporarily tighten the rack end.
  HINT:
  
  Align the claws of the washer with the steering rack grooves.
  
  Fig 13: Aligning Claws Of Washer With Steering Rack Grooves
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
  SST 09922-10010
  
  Torque: 99 N*m (1,014 kgf*cm, 74 ft.*lbf)
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  HINT:
  
  Use a torque wrench with a fulcrum length of 380 mm (13.58 in.).
  
  Fig 14: Identifying Fulcrum Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a brass bar and hammer, stake the washer.
  NOTE: Avoid any impact to the rack.
4. Use the same procedure described above for the other side.
  
  Fig 15: Staking Washer Using Brass Bar & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RACK BOOT, CLAMP AND CLIP
1. Ensure that the tube hole is not clogged with grease.
  HINT:
  
  If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
  
  Fig 16: Identifying Tube Hole
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the boot.
  NOTE: Be careful not to damage or twist the boot.
3. Using pliers, tighten a new clamp as shown.
4. Use the same procedure described above for the other side.
  
  Fig 17: Tightening New Clamp Using Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2 TURN PRESSURE TUBES
1. Using SST, install the tube.
  SST 09023-38201
  
  Torque: 23 N*m (230 kgf*cm, 17 ft.*lbf)
  
  HINT:
  - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
  - This torque valve is effective in case that SST is parallel to a torque wrench.
    
    Fig 18: Identifying Fulcrum Length
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002