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Home >> Lexus >> 2000 >> ES 300 V6-3.0L (1MZ-FE) >> Repair and Diagnosis >> Steering and Suspension >> Steering >> Steering Gear >> Service and Repair >> Disassembly and Assembly

Disassembly and Assembly









DISASSEMBLY

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





1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012





2. REMOVE 2 TURN PRESSURE TUBES
a. Using SST, remove the tube.
SST 09633-00020
b. Remove the 2 O-rings from the tube





3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS
a. Place matchmarks on the tie rod end and rack end.
b. Loosen the lock nut.





4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS Using a screwdriver, loosen the clamp.

NOTICE: Be careful not to damage the boot. Mark the RH and LH boots.

5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS





a. Using a screwdriver and hammer, unstake the washer.

NOTICE: Avoid any impact on the steering rack.





b. Using a spanner (24 mm) to hold the steering rack steadily, and using SST, remove the rack end.
SST 09922-10010

NOTICE:
^ Use SST 09922-10010 in the direction shown in the illustration.
^ Mark the RH and LH rack ends.

c. Remove the washer from the rack end.





6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010

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





7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE AND RACK GUIDE SEAT
a. Using SST, remove the cap.
SST 09631-10021
b. Remove the seat from the guide.
8. REMOVE RACK HOUSING CAP





9. REMOVE SELF-LOCKING NUT
Using SST to stop the control valve shaft rotating, remove the nut.
SST 09616 - 00010
10. REMOVE DUST COVER





11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the valve housing and rack housing.
b. Remove the 2 bolts.
c. Remove the gasket from the rack housing.





12. REMOVE CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Press out the valve assembly with the oil seal.

NOTICE: Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
^ Be careful not to damage the oil seal lip.

13. REMOVE OIL SEAL
Remove the oil seal from the control valve assembly.
14. REMOVE RACK HOUSING NO.2 BRACKET AND GROMMET





a. Place matchmarks on the bracket and rack housing.





b. Using a screwdriver, pry the clamp of the bracket.
c. Remove the grommet from the bracket.





15. REMOVE CYLINDER END STOPPER
a. Using SST, turn the stopper clockwise until the wire end is visible through the service hole.
SST 09631-10021
b. Using SST, turn the stopper counterclockwise, and remove the wire.
SST09631-10021





16. REMOVE STEERING RACK AND BUSHING
a. Using a brass bar and hammer, tap out the rack with the bushing.
b. Remove the bushing from the rack.
c. Remove the O-ring from the bushing.





17. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00290), 09950-70010 (09951-07360)


INSPECTION

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





1. INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout, teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.
2. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07200)
b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07200)

NOTICE: Make sure to install the oil seal facing the correct direction.

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





e. Using SST, press in the bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-7200)
3. IF NECESSARY, REPLACE 2 BEARINGS





a. Using a brass bar and hammer, tap out the bearing from the rack housing.





b. Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07200)
c. Coat a new bearing with molybdenum disulfide lithium base grease.





d. Using SST, press in the bearing.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07200)





e. Coat a new bearing with molybdenum disulfide lithium base grease.
f. Using SST, press in the bearing.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07200)
4. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, remove the oil seal from the bushing.
SST 09527-20011, 09612-24014 (09613-22011)

NOTICE: Be careful not to damage the bushing.





b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00400, 09952-06010)

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

5. IF NECESSARY, REPLACE TEFLON RING AND O-RING





a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.

NOTICE: Be careful not to damage the groove for the teflon ring.

b. Coat a new O-ring with power steering fluid and install it.





c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to over-expand the ring.





d. Coat the ring with power steering fluid.
e. Install the ring to the steering rack, and settle it down with your fingers.
6. IF NECESSARY, REPLACE TEFLON RINGS





a. Using a screwdriver, remove the 4 rings from the control valve assembly.

NOTICE: Be careful not to damage the grooves for the teflon ring.

b. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to over-expand the teflon ring.

c. Coat the rings with power steering fluid.
d. Install the rings to the control valve assembly, and settle them down with your fingers.





e. Carefully slide the tapered end of SST over the rings until it fits to the steering rack. SST 09631 -20081

NOTICE: Be careful not to damage the rings.


REASSEMBLY

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







1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE





2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure that the oil seal is installed facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.





3. INSTALL STEERING RACK
a. Install SST to the rack.
SST 09631-33010

HINT: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid
c. Install the rack into the rack housing

NOTICE: Be careful not to damage the oil seal lip.

d. Remove SST.





4. INSTALL BUSHING
a. Coat a new O-ring with power steering fluid and install it to the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid
c. Install the bushing.

NOTICE:
^ Make sure to install the bushing facing the correct direction.
^ Be careful not to damage the oil seal lip.





5. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the stopper with the slot of the rack housing.
b. Install a new wire into the stopper.
c. Using SST, turn the stopper clockwise 45° ± 50°.
SST 09631-10021





6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.
7. INSTALL RACK HOUSING NO.2 BRACKET AND GROMMET
a. Install the grommet to the bracket.





HINT: Align the projection of the grommet with the hole of the bracket.

b. Align the matchmarks on the bracket and rack housing.





c. Place the bracket in a vise and tighten the vise to fasten the clamp.





8. INSTALL CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Coat the teflon rings with power steering fluid.
c. Install the valve assembly into the valve housing.

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





9. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09612-22011

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

10. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the valve housing and rack housing.
c. Torque the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





11. INSTALL SELF-LOCKING NUT
Using SST to stop the control valve shaft rotating, torque a new nut.
SST 09616-00010
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
12. INSTALL DUST COVER





13. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Torque the cap.
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
c. Using a punch and hammer, stake the 2 parts of the cap.
14. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the seat to the guide.
b. Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the cap.





15. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
b. Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 Nm (250 kgf cm, 18 ft. lbs.)





c. Using SST, return the cap 12°
SST09631-10021





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00010
e. Using SST, loosen the cap until the rack guide spring is not functioning.
SST 09631-10021





f. Using SST and a torque wrench, tighten the cap until preload is within specification.
SST 09610-00010, 09631-10021
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf cm, 6.9 - 12.2 inch lbs.)





16. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.088300080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST to hold the rack guide spring cap, and using SST, torque the nut.
SST 09631-10021, 09922-10010
Torque: 50 Nm (513 kgf-cm, 37 ft. lbs.)

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

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.53 inch).

c. Recheck the total preload.
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf-cm, 6.9 - 12.2 inch lbs.)
d. Remove the RH and LH rack ends.





17. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS
a. Install a new claw washer, and temporarily install the rack end.

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





b. Using a spanner (24 mm) to hold the steering rack steady, and using SST, torque the rack end.
SST 09922-10010
Torque: 60 Nm (615 kgf-cm, 45 ft. lbs.)

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

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).





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

NOTICE: Avoid any impact on the rack.





18. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Ensure that the steering rack hole is not clogged with grease.

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





b. Install the boot.

NOTICE: Be careful not to damage or twist the boot.

c. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
19. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, torque the nut.
Torque: 74 Nm (750 kgf cm, 54 ft. lbs.)





20. INSTALL 2 TURN PRESSURE TUBES
a. Coat 2 new O-rings with power steering fluid and install them to the tube.
b. Using SST, install the tube.
SST 09633-00020
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 250 mm (9.84 inch). This torque value is effective in case that SST is parallel to a torque wrench.

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