STEERING GEAR REASSEMBLY


  1. INSTALL POWER PISTON OIL SEAL

    A01KHYP

    1. Coat a new oil seal with power steering fluid and install it.

    2. Expand a new teflon ring with your fingers.

      Note

      Be careful no to overexpand the ring.

    3. Coat the ring with power steering fluid.

    4. A01KEHW

      Install the ring to the rack, and settle it down with your fingers.

      Note

      Be careful not to damage the oil seal.

  2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL

    A01KHKDE01

    1. Coat the spacer with power steering fluid.

    2. Coat a new oil seal lip with power steering fluid.

    3. Using SST, press in the spacer and oil seal.

      SST
      09950-60010   ( 09951-00300, 09951-00470, 09952-06010 )
      09950-70010   ( 09951-07360 )

      Note


      • Make sure to install the oil seal facing in the correct direction.

      • Take care that the oil seal does not get reversed as you install it.

      Tech Tips

      Install the cylinder end stopper temporarily to make it be a guide for SST.

  3. INSTALL POWER STEERING RACK

    A01KEIZE01

    1. Coat SST with power steering fluid.

      SST
      09631-00350

    2. Install SST to the rack.

      Text in Illustration
      *a Rack Teeth End

      Tech Tips

      Is necessary, scrape the burrs off the rack teeth end and burnish.

    3. Install the rack into the rack housing.

    4. Remove the SST.

    5. A01KII3E01

      Coat SST with power steering fluid.

      SST
      09631-00350

    6. Install SST to the steering rack opposite end.

    7. Coat a new oil seal lip with power steering fluid, and install the oil seal by pushing it without tilting.

      Note


      • Make sure to install the oil seal facing in the correct direction.

      • Be careful not to damage the oil seal lip.

    8. Remove the SST.

  4. INSTALL CYLINDER END STOPPER

    A01KH37

    1. Coat a new O-ring with power steering fluid, and install it to the stopper.

    2. Using a wooden block and a hammer, drive in the stopper until it is tightly installed.

      Note

      Be careful no to damage the O-ring.

    3. A01KGJ2E01

      Using SST, torque the stopper.

      SST
      09631-36010
      Torque:
      78 N*m  { 795 kgf*cm, 57 ft.*lbf }

  5. AIR TIGHTNESS TEST

    A01KEDFE01

    1. Install SST to the unions of the rack housing.

      SST
      09631-12071   ( 09633-00010 )

    2. Apply 53.33 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.

  6. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL

    A01KGKWE01

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

    2. Using SST, press in the oil seal.

      SST
      09950-60010   ( 09951-00180, 09951-00320, 09951-00340, 09952-06010 )
      09950-70010   ( 09951-07150 )

      Note

      Make sure to install the oil seal facing in the correct direction.

    3. Coat a new bearing with molybdenum disulfide lithium base grease.

    4. A01KGURE01

      Using SST, press in the baring.

      SST
      09950-60010   ( 09951-00180, 09951-00320, 09951-00340, 09952-06010 )
      09950-70010   ( 09951-07150 )

  7. INSTALL POWER STEERING CONTROL VALVE

    A01KIMZ

    1. Using a plastic hammer and a sliding handle, lightly tap in a new union seat.

      Note

      Before installing the union seat, remove dust sticking to the control valve housing.

    2. Coat the rings with power steering fluid.

    3. A01KHYP

      Expand 4 new rings with your fingers.

      Note

      Be careful not to overexpand the ring.

    4. A01KGDEE01

      Install the rings to the control valve assembly, and settle them down with your fingers.

    5. Carefully slide the tapered end of SST over the rings until the ring fits to the steering rack.

      SST
      09631-20081

      Note

      Be careful not to overexpand the ring.

    6. Coat the teflon rings with power steering fluid.

    7. A01KIC4E01
      Text in Illustration
      *1 Vinyl Tape

      To prevent oil seal lip damage, wind vinyl tape on the serrated port of the control valve shaft.

    8. Push the valve assembly into the control valve housing.

      Note

      Be careful not to damage the teflon rings and oil seal lip.

    9. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.

    10. Coat a new oil seal lip with power steering fluid.

    11. A01KGC2E01

      Using SST and a hammer, drive in the oil seal.

      SST
      09950-60010   ( 09951-00390 )
      09950-70010   ( 09951-07100 )

      Note

      Make sure to install the oil seal facing in the correct direction.

    12. Lightly mount the control valve assembly between aluminum plates in a vise.

    13. To prevent oil seal lip damage, wind vinyl tape on the pinion part of the control valve shaft.

    14. A01KERQE01
      Text in Illustration
      *1 Vinyl Tape

      Using SST, torque the guide 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.

    15. A01KFS0

      Using a punch and a hammer, stake the nut.

    16. Coat a new O-ring with power steering fluid, and install it to the valve housing.

    17. A01KIGUE01
      Text in Illustration
      *a Grease filling

      Apply molybdenum disulfide base grease for the needle roller baring inside the rack housing in the illustrated portion.

      Volume of grease applied
      Approximately 2 g (0.07 oz)

    18. Install the control valve assembly with the 2 bolts.

      Torque:
      18.1 N*m  { 184 kgf*cm, 13 ft.*lbf }

  8. INSTALL RACK GUIDE

    A01KFB3E01
    Text in Illustration
    *1 Hexagon Wrench

    1. Install the rack guide and spring.

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

      Sealant
      Toyota Genuine Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent

    3. Using a hexagon wrench (24 mm), temporarily install the spring cap.

  9. 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. A01KFB3E01
      Text in Illustration
      *1 Hexagon Wrench

      Using a hexagon wrench (24 mm), tighten the rack guide spring cap.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Return the cap 30°.

    4. A01KI3GE01

      Using SST, turn the control valve shaft right and left 1 or 2 times.

      SST
      09616-00011

    5. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring is not functioning.

    6. A01KIF8E01
      Text in Illustration
      *1 Hexagon Wrench

      Using SST, a torque wrench and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

      SST
      09616-00011
      Preload (turning)
      0.8 - 1.2 N*m (8.1 - 12.2 kgf*cm, 7.1 - 10.6 in.*lbf)

      Note

      Adjustment should be done in the tightening direction of the spring cap.

    7. Apply sealant to 2 or 3 threads of the lock nut.

      Sealant
      Toyota Genuine Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent

    8. Temporarily install the lock nut.

    9. A01KFVCE01
      Text in Illustration
      *1 Hexagon Wrench

      Using a hexagon wrench (24 mm), holding the rack guide spring cap rotating, and using SST, torque the nut.

      SST
      09922-10010
      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf, for use with SST }

      Note

      Use SST 09922-10010 in the direction shown in the illustration.

      Tech Tips

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

    10. A01KI3GE01

      Recheck the total preload.

      Preload (turning)
      0.8 - 1.2 N*m (8.1 - 12.2 kgf*cm, 7.1 - 10.6 in.*lbf)

    11. Remove the RH and LH rack ends.

  10. INSPECT POWER STEERING RACK

    A01KI2A

    1. Insert a wire into the vent hole of the steering rack by 30 mm(1.18 in.), and ensure that the vent hole is not clogged with grease.

      Tech Tips

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

  11. INSTALL STEERING RACK END SUB-ASSEMBLY


    1. Install a new claw washer, and temporarily tighten the rack end.

      Tech Tips

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

    2. A01KH2AE01

      Using SST to hold the steering rack steady, and using SST, torque the rack end RH.

      SST
      09922-10010
      Torque:
      74.3 N*m  { 758 kgf*cm, 55 ft.*lbf, for use with SST }

      Note

      Use SST 09922-10010 in the direction shown in the illustration.

      Tech Tips

      Use a torque wrench with a fulcrum length of 380 mm (14.9 in.).

    3. A01KI70E01

      Using SST to hold the steering rack steady, and using SST, torque the rack end LH.

      Torque:
      74.3 N*m  { 758 kgf*cm, 55 ft.*lbf, for use with SST }

      Note

      Use SST 09922-10010 in the direction shown in the illustration.

      Tech Tips

      Use a torque wrench with a fulcrum length of 380 mm (14.9 in.).

    4. A01KHMEE05
      Text in Illustration
      *1 Brass Bar

      Using a brass bar and a hammer, stake the washer.

      Note

      Avoid any impact to the rack.

    5. Employ the same manner described above to the other side.

  12. INSTALL STEERING RACK BOOT NO.1


    1. Install the boot.

      Note

      Be careful not to damage or twist the boot.

  13. INSTALL STEERING RACK BOOT NO.2

    Note

    Install the No.2 side by the same procedures with the No.1 side.

  14. INSTALL STEERING RACK BOOT NO.1 CLAMP

    A01KHHR

    1. Using pliers and a screwdriver, install the clamp.

    2. Install the clip.

    3. Employ the same manner described above to the other side.

  15. INSTALL STEERING RACK BOOT NO.2 CLAMP

    Tech Tips

    Install the No.2 side by the same procedures with the No.1 side.

  16. INSPECT RACK & PINION POWER STEERING GEAR ASSEMBLY

    A01KGSBE01

    1. Using SST, check that the rack boot stretches smoothly when the control valve shaft is being rotated.

      SST
      09616-00011
    2. A01KFBBE01
      Text in Illustration
      *a Grease filling

      Apply MP grease in the illustrated portion.

    3. Install the dust cover.

    4. Using a union nut wrench, install the 2 turn pressure tubes.

      Torque:
      22 N*m  { 223 kgf*cm, 16 ft.*lbf, for use with union nut wrench }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective in case that a union nut wrench is parallel to a torque wrench.

  17. INSTALL TIE ROD END SUB-ASSEMBLY LH


    1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.

    2. After adjusting toe-in, torque the nut.

    3. Employ the same side manner described above to the other side.

  18. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

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