STEERING GEAR REASSEMBLY

Note

When installing, coat the parts indicated by arrows with power steering fluid, silicon grease and molybdenum disulfide lithium base grease Click here.


  1. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL


    1. Install the spacer to the power steering rack housing.

      Note

      Do not damage the inside of the power steering rack housing.

    2. Apply power steering fluid to the lip of a new power steering cylinder tube oil seal.

    3. A003DO5E01

      Install the power steering cylinder tube oil seal to the rack housing at a slant.

      SST
      09950-70010   ( 09951-07360 )
      09631-00210

      Note


      • Ensure the power steering cylinder tube oil seal is installed in the correct direction as shown in the illustration.

      • Install the power steering cylinder tube oil seal at an angle of approximately 15° so that the lowermost part comes to the point, indicated by the arrow in the illustration, to prevent damage to the side of the oil seal when it passes the 2 ports.

    4. Using SST, insert the power steering cylinder tube oil seal by pushing the SST in by hand until the oil seal passes the 2 ports.

      Note

      Do not turn the SST when inserting the oil seal.

    5. Install SST (09631-00210) to SST (09951-07360) upside down.

      SST
      09950-70010   ( 09951-07360 )
      09631-00210
    6. A003F35E01

      Using SST, level the power steering cylinder tube oil seal by pushing the SST in by hand.

      SST
      09950-70010   ( 09951-07360 )
      09631-00210
    7. A003AGEE01

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

  2. INSTALL POWER STEERING RACK


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

    2. A003G6B

      Expand a new oil seal with your fingers.

    3. Coat the oil seal with power steering fluid.

    4. A003FKL

      Install the oil seal to the steering rack, and adjust with your fingers.

    5. A003D4NE01

      Apply molybdenum disulfide lithium base grease to the rack teeth ends.

      Tech Tips

      If necessary, scrape the burrs off the rack teeth ends and burnish.

    6. Affix SST to the steering rack.

      SST
      09631-20111

    7. Coat SST with power steering fluid.

    8. Install the steering rack to the rack housing.

    9. Remove the SST.

  3. INSTALL CYLINDER END STOPPER


    1. Body type narrow:


      1. A003ANZE01

        Wrap protective tape around the RH side of the power steering rack and apply power steering fluid.

      2. Apply power steering fluid to the lip of a new cylinder end stopper oil seal.

      3. Install the cylinder end stopper oil seal to the RH side of the rack housing.

        Note


        • Ensure that the cylinder end stopper oil seal is installed in the correct direction as shown in the illustration.

        • Do not damage the cylinder end stopper oil seal.

      4. Remove the protective tape from the power steering rack.

      5. Apply power steering fluid to a new cylinder end stopper O-ring.

      6. Install the cylinder end stopper O-ring to the cylinder end stopper.

      7. A003FTEE01

        Install a new cylinder end stopper bushing to the cylinder end stopper.

      8. Apply molybdenum disulfide lithium base grease to the entire inner side of the cylinder end stopper.

      9. Install the tube support retainer.

      10. A003HOAE01

        Using SST, install the cylinder end stopper to the rack housing.

        SST
        09631-20120
        Torque:
        78 N*m  { 795 kgf*cm, 58 ft.*lbf }
      11. A003F2WE01

        Tighten the bolt.

        Torque:
        19 N*m  { 195 kgf*cm, 14 ft.*lbf }

    2. Body type wide:


      1. A003ANZE01

        Wrap protective tape around the RH side of the power steering rack and apply power steering fluid.

      2. Apply power steering fluid to the lip of a new cylinder end stopper oil seal.

      3. Install the cylinder end stopper oil seal to the RH side of the rack housing.

        Note


        • Ensure that the cylinder end stopper oil seal is installed in the correct direction as shown in the illustration.

        • Do not damage the cylinder end stopper oil seal.

      4. Remove the protective tape from the power steering rack.

      5. Install the spacer to the rack housing.

      6. Apply power steering fluid to a new cylinder end stopper O-ring.

      7. Install the cylinder end stopper O-ring to the cylinder end stopper.

      8. Install a new cylinder end stopper bushing to the cylinder end stopper.

      9. A003BWRE01

        Apply molybdenum disulfide lithium base grease to the entire inner side of the cylinder end stopper.

      10. A003HCGE01

        Using SST, install the cylinder end stopper to the rack housing.

        SST
        09631-20120
        Torque:
        78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  4. AIR TIGHTNESS TEST


    1. A003F8ME01

      Install SST and a vacuum pump to the rack housing.

      SST
      09631-12071   ( 09633-00010 )

    2. Apply a vacuum of 53 kPa (398 mmHg, 15.65 in.Hg) for approximately 30 seconds.

    3. Check that there is no change in the vacuum pressure.

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

  5. INSTALL POWER STEERING CONTROL VALVE ASSEMBLY


    1. A003APME01

      Install the power steering control valve assembly and a new gasket to the rack housing with the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  6. INSTALL STEERING RACK GUIDE


    1. Install the rack guide seat to the power steering rack guide.

    2. Apply molybdenum disulfide lithium base grease to the compression spring and the contact surface of the rack guide seat and the power steering rack.

    3. Install the compression spring and the rack guide.

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

      Sealant
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    5. Using a straight hexagon wrench 24 mm (0.94 in.), install the rack guide spring cap.

  7. INSPECT TOTAL PRELOAD


    1. Using a straight hexagon wrench 24 mm (0.94 in.), tighten the power steering rack guide spring cap.

      Torque:
      69 N*m  { 704 kgf*cm, 51 ft.*lbf }

    2. Using a straight hexagon wrench 24 mm (0.94 in.), loosen the power steering rack guide spring cap.

    3. Temporarily install the steering rack ends to prevent steering rack over stroke.

      Note

      Do not fully turn the power steering rack without the steering rack end as it may damage the oil seal in the rack housing and the cylinder end stopper bushing.

    4. A003E91E01

      Using SST, fully turn the power steering rack right and left 10 times to settle.

      SST
      09616-00011
    5. A003CMAE01

      Using a straight hexagon wrench 24 mm (0.94 in.), tighten the power steering rack guide spring cap in small amounts until the preload is within the specified range.

      SST
      09616-00011
      Preload (turning)
      0.65 to 1.35 N*m (6.6 to 13.8 kgf*cm, 5.8 to 11.9 in.*lbf)

      Note

      Loosen and tighten the power steering rack guide spring cap again if the preload falls below the specified range.

    6. A003HZHE01

      Using SST, install the power steering rack guide spring cap nut.

      SST
      09922-10010
      Torque:
      49 N*m  { 502 kgf*cm, 36 ft.*lbf }

      Note


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

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

    7. A003CMAE01

      Using SST, inspect the total preload.

      SST
      09616-00011
      Preload (turning)
      0.65 to 1.35 N*m (6.6 to 13.8 kgf*cm, 5.8 to 11.9 in.*lbf)

  8. INSTALL RACK END SUB-ASSEMBLY


    1. Install 2 new claw washers.

      Tech Tips

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

    2. A003BU3E01

      Using SST, install the steering rack end sub-assembly (RH side).

      SST
      09922-10010
      Torque:
      72 N*m  { 736 kgf*cm, 53 ft.*lbf }

      Note


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

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

      Tech Tips

      Using SST, hold the steering rack and install the steering rack end sub-assembly.

    3. A003HVAE01

      Using SST, install the steering rack end sub-assembly (LH side).

      SST
      09922-10010
      Torque:
      72 N*m  { 736 kgf*cm, 53 ft.*lbf }

      Note


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

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

    4. A003F6K

      Using a brass bar and a hammer, stake the 2 claw washers.

      Note

      Avoid any impact to the steering rack.

  9. INSTALL STEERING RACK BOOT NO.2


    1. A003CJX

      Apply silicon grease to the inside of the small opening of the steering rack boot No.2.

    2. A003EYDE01

      Temporarily install a new steering rack boot No.2 clamp to the large opening of the steering rack boot No.2 at the position shown by arrow (A).

      Note


      • Use a new steering rack boot No.2 clamp.

      • Do not expand the steering rack boot No.2 clamp more than necessary for installation.

      • Do not deform the steering rack boot No.2 clamp.

      • Tightening force of the steering rack boot No.2 clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the boot and rack housing, causing a malfunction.

      • Use only the supply parts which are applicable to the vehicle to secure the boot.

      Tech Tips

      After disengaging the claw of a new steering rack boot No.2 clamp, temporarily install it from the end without expanding the clamp diameter more than necessary.

    3. Install the rack boot No.2 to the groove on the rack housing.

      Note


      • Be careful not to damage or twist the boot.

      • Do not damage the steering rack boot No.2.

      • Ensure that the steering rack boot No.2 clamp is installed before installing the steering rack boot No.2 to the rack housing.

  10. INSTALL STEERING RACK BOOT NO.1

    Tech Tips

    Perform the same procedure as for the steering rack boot No.2.

  11. INSTALL STEERING RACK BOOT NO.2 CLAMP


    1. A003AX8

      Using pliers and a screwdriver, install the steering rack boot No.2 clamp.

      Note


      • Be careful not to damage the steering rack boot.

      • Do not twist the steering rack boot.

  12. INSTALL STEERING RACK BOOT NO.1 CLAMP

    Tech Tips

    Perform the same procedure as for the steering rack boot No.2 clamp.

  13. INSTALL STEERING RACK BOOT CLIP


    1. Using pliers, install the 2 boot clips.

    2. A003CGTE01

      Using SST, turn the pinion and check that the rack boots expand and contract smoothly.

      SST
      09616-00011

  14. INSTALL TIE ROD END SUB-ASSEMBLY LH


    1. A003F0CE01

      Install the lock nut and the tie rod sub-assembly LH to the rack end sub-assembly until the matchmarks are aligned.

      Tech Tips

      After adjusting toe-in, torque the lock nut.

  15. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  16. INSTALL STEERING RIGHT TURN PRESSURE TUBE


    1. A003E0TE02

      Using a union nut wrench, install the steering right turn pressure tube.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Note

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

  17. INSTALL STEERING LEFT TURN PRESSURE TUBE


    1. A003CPEE02

      Using a union nut wrench, install the steering left turn pressure tube.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Note

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