Part 2

RACK AND PINION POWER STEERING GEAR(continued)

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REASSEMBLY

1. INSTALL POWER PISTON OIL SEAL
(a) Coat a new O-ring with power steering fluid and install it on the steering rack.
(b) Expand a new oil seal with your fingers.

NOTICE: Be careful not to overexpand the oil seal.

(c) Coat the "Teflon" ring with power steering fluid.

(d) Install the power piston oil seal to the power steering rack's groove.
Grip the ring to press it into the groove.

2. INSTALL POWER STEERING RACK HOUSING OIL SEAL
(a) Apply power steering fluid to a new oil seal, and install the oil seal on the rack housing at an angle.

NOTICE: Install the oil seal in the correct direction.

HINT: Install the oil seal so that the port faces downward approximately 15 degrees.

(b) Using SST, push in the oil seal by hand until it passes through the 2 ports.
SST 09950-70010 (09951-07360)

NOTICE: Do not turn SST when inserting the oil seal.

(c) Using SST, push in the oil seal by hand until it becomes level.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

NOTICE: When SST is set, do not damage the inside surface of the rack housing.

(d) Using SST and a press, install the oil seal.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)

3. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
(a) Install SST to the power steering rack.
SST 09631-20102

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

(b) Coat SST and the power piston seal with power steering fluid.
(c) Install the steering rack to the power steering rack housing.

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

(d) Remove SST.
SST 09631-20102

(e) Coat SST with power steering fluid.
(f) Install SST to the steering rack opposite end.
(g) Coat a new oil seal lip with power steering fluid, and install the oil seal by pushing it without tilting it.

NOTICE:
^ Make sure that the oil seal is installed facing the correct direction.
^ Be careful not to damage the oil seal lip.

(h) Remove SST.

(i) Using SST and a hammer, tap in the power steering cylinder housing spacer.
SST 09950-60010 (09951-00280, 09951-00420, 09952-06010), 09950-70010 (09951-07200)

4. INSTALL CYLINDER END STOPPER
(a) Coat a new O-ring with power steering fluid, and install it to the cylinder end stopper.
(b) Using a wooden block and hammer, tap in the cylinder end stopper until it is tightly installed.

NOTICE: Be careful not to damage the O-ring.

5. AIRTIGHTNESS TEST
(a) Install SST to the unions of 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 a change in the vacuum, check the installation of the oil seals.

6. INSTALL POWER STEERING CONTROL VALVE LOWER OIL SEAL
(a) Coat a new control valve lower oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100)

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

7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Coat a new control valve upper oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)

(c) Coat a bearing with molybdenum disulfide lithium base grease.
(d) Using SST, press in the bearing.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)

8. INSTALL POWER STEERING CONTROL VALVE
(a) Coat the control valve rings with power steering fluid.
(b) Install the control valve rings to the control valve. Grip the rings to press them in.
(c) Carefully slide the tapered end of SST over the control valve rings until the control valve ring fits to the steering rack.
SST 09631-20081

NOTICE: Be careful not to overexpand the control valve rings.

(d) Coat the control valve rings with power steering fluid.
(e) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve shaft.
(f) Push the control valve into the control valve housing.

NOTICE: Be careful not to damage the control valve rings and oil seal lip.

(g) Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
(h) Using SST, torque the bearing guide nut.
SST 09631-20060

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

(i) Using a punch, stake the bearing guide nut.
(j) Coat a new O-ring with power steering fluid, and install it to the control valve housing.
(k) Align the matchmarks on the control valve housing and rack housing, and install the control valve housing with the control valve to the rack housing.
(l) Install the 2 bolts.
Torque: 18 N*m (180 kgf*cm, 13 ft.*lbf)
(m) Install steering gear dust cover.
9. INSTALL RACK GUIDE
(a) Install the rack guide seat to the steering gear rack guide.
(b) Install the rack guide, conical spring washer and steering rack guide spring.
(c) Apply adhesive to 2 or 3 threads of the steering rack guide spring cap.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(d) Temporarily install the rack guide spring cap.

10. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack ends.
(b) Tighten the steering rack guide spring cap.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
SST 09616-00011
(c) Loosen the spring cap 17°.

(d) Using SST, turn the control valve shaft right and left 1 or 2 times. The rack end will move in and out.
(e) Loosen the steering rack guide spring cap until the steering rack guide spring is not functioning.

(f) Using SST and a torque wrench, tighten the spring cap until the preload is within the specification.
SST 09616-00011
Standard preload (turning): 0.5 to 1.7 N*m (4.7 to 17.2 kgf*cm, 4.1 to 14.9 in.*lbf)

(g) Apply adhesive to 2 or 3 threads of the steering spring cap nut.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
(h) Using a wrench, hold the spring cap. Using SST, torque the rack guide spring nut.
SST 09922-10010
Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf)

NOTICE: Rotate SST in the direction shown in the illustration.

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

(i) Recheck the total preload.
Standard preload (turning): 0.5 to 1.7 N*m (4.7 to 17.2 kgf*cm, 4.1 to 14.9 in.*lbf)
(j) Remove the RH and LH steering rack ends.

11. INSTALL STEERING RACK END CLAW WASHER
(a) Install a new claw washer and temporarily tighten the rack end.

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

(b) Use the same procedure described for the other side.

12. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Using a wrench, hold the power steering rack steadily. Using SST, torque the steering rack end.
SST 09922-10010
Torque: 76 N*m (770 kgf*cm, 56 ft.*lbf)

NOTICE: Rotate SST in the direction shown in the illustration.

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

(b) Using a brass bar and hammer, stake the steering claw washer.

NOTICE: Avoid any impact to the rack.

(c) Use the same procedure described for the other side.

13. INSTALL NO. 1 STEERING RACK BOOT
(a) Ensure that the steering rack hole is not clogged with grease.

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

(b) Install the steering rack boot.
14. INSTALL NO. 2 STEERING RACK BOOT

HINT: Use same procedures described for the No. 1 steering rack boot.

15. INSTALL NO. 1 STEERING RACK BOOT CLAMP
(a) Using pliers, tighten a new clamp as shown in the illustration.

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

16. INSTALL NO. 2 STEERING RACK BOOT CLAMP

HINT: Use the same procedure described for the rack boot No. 1 clamp.

17. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install 2 clips.

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

18. INSTALL TIE ROD ASSEMBLY LH
(a) Screw the lock nut and tie rod LH onto the steering rack end until the matchmarks are aligned.
(b) After adjusting toe-in, tighten the nut.
Torque: 56 N*m (570 kgf*cm, 41 ft.*lbf)
19. INSTALL TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the tie rod LH.

INSTALLATION

1. INSTALL RACK AND PINION POWER STEERING GEAR ASSEMBLY
(a) Install 2 new steering turn pressure tube union seats to the rack housing.
(b) Using SST, install the steering left turn pressure tube and steering right turn pressure tube.
SST 09023-38200
Torque: 23 N*m (240 kgf*cm, 17 ft.*lbf)

HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
^ This torque value is applicable only if SST is parallel to the torque wrench.

(c) Install the grommet and steering rack housing bracket No. 2 to the rack and pinion power steering gear.
(d) Install the rack and pinion power steering gear with the 4 gear set bolts.
Torque: 65 N*m (660 kgf*cm, 48 ft.*lbf)
(e) Connect the connector.
(f) Connect the 2 tube clamps with the bolt.
Torque: 5.0 N*m (55 kgf*cm, 48 in.*lbf)
2. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY

3. CONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Pressure feed tube:
Install a new gasket. Then connect the pressure feed tube with the union bolt.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
(b) Return tube:
Install 2 new gaskets on each side of the return tube and connect the return tube with the union bolt.
Torque: 49 N*m (250 kgf*cm, 36 ft.*lbf)
4. CONNECT TIE ROD ASSEMBLY LH
(a) Connect the tie rod to the lower ball joint and install the clip and nut.
Torque: 87 N*m (890 kgf*cm, 64 ft.*lbf)
(b) Install the 2 nuts and caliper.
Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)
5. CONNECT TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

6. INSPECT CENTER FRONT WHEEL

HINT: Inspect with the front of the vehicle jacked up.

7. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY
(a) Install the brace with the 4 bolts.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)

8. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH
(a) Install the brace with the bolt and nut.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)

9. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
(a) Install the brace with the bolt and nut.
Torque: 58 N*m (590 kgf*cm, 43 ft.*lbf)
10. INSTALL NO. 2 ENGINE UNDER COVER
11. CENTER SPIRAL CABLE SUB-ASSEMBLY
12. TEMPORARILY TIGHTEN STEERING WHEEL ASSEMBLY
(a) Align the matchmarks on the wheel and steering column main shaft.
(b) Temporarily install the steering wheel set nut.
(c) Connect the connector.
13. BLEED AIR FROM POWER STEERING SYSTEM)
14. INSPECT POWER STEERING CENTER POINT
15. INSTALL STEERING WHEEL ASSEMBLY
16. INSTALL STEERING PAD ASSEMBLY
17. INSTALL NO. 2 STEERING WHEEL COVER LOWER
18. INSTALL STEERING PAD SWITCH MODULATOR
19. INSTALL SWITCH AND VOLUME CASE
20. INSTALL FRONT WHEELS
(a) Install the wheels with the 10 nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Install the ornaments with the 20 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
21. ADJUST FRONT WHEEL ALIGNMENT
(a) Adjust the front wheel alignment.
22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
23. INSPECT SRS WARNING LIGHT
(a) Inspect the SRS warning light.
24. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.