FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Toyota Truck >> 2000 >> Tacoma PreRunner Extra Cab 2WD L4-2.7L (3RZ-FE) >> Repair and Diagnosis >> Steering and Suspension >> Steering >> Steering Gear >> Service and Repair >> With Manual Steering >> Disassembly and Reassembly

Disassembly and Reassembly

Part 1 Of 2:




Part 2 Of 2:






DISASSEMBLY

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





1. SECURE MANUAL STEERING GEAR IN VISE
Using SST and 2 bolts, secure the gear assembly in a vise, as shown in the illustration.
SST 09612-00012
Reference:
Bolt: 90105-10017
Nut: 90170-10198

HINT: Use 2 of the same type of SST.





2. REMOVE RH AND LH TIE ROD ENDS AND LOCKNUTS
Place matchmarks on the tie rod end and rack end.





3. 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.

4. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS





a. Using a screwdriver and hammer, stake back the washer.

NOTICE: Avoid any Impact to the steering rack.





b. Using a spanner to hold the steering rack steady, 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.





5. REMOVE RACK HOUSING NO.2 BRACKET AND GROMMET
a. Place matchmarks, on the bracket and rack housing.
b. Remove the bolt.





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 DUST COVER
9. REMOVE PINION BEARING ADJUSTING SCREW LOCK NUT
Using SST, remove the nut.
SST 09922-10010

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





10. REMOVE PINION BEARING ADJUSTING SCREW
Using SST, remove the screw.
SST 09922-10010

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





11. REMOVE STEERING PINION ASSEMBLY
a. Fully pull the steering rack from the pinion housing side of the rack housing and align the cutout portion of the rack with the pinion assembly.
b. Remove the pinion assembly from the rack housing.
12. REMOVE STEERING RACK
Remove the rack from the rack housing without revolving it.

NOTICE: Remove the rack from the steering pinion housing side of the rack housing, as shown.

INSPECTION

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





1. INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout and for teeth wear and damage.
Maximum runout: 0.30 mm (0.0118 inch)
b. Check the back surface for wear and damage.





2. INSPECT BEARING
a. Check the needle roller bearing for pitmarks or damage. If faulty, replace the rack housing.
b. Apply molybdenum disulfide lithium base grease to the inside of the bearing.





3. IF NECESSARY, REPLACE BUSHING
a. Using a screwdriver, loosen the 3 claws of the bushing, and remove the bushing from the rack housing.
b. Coat a new bushing with molybdenum disulfide lithium base grease.
c. Install the bushing into the rack housing, making sure to align with the 3 holes.





4. INSPECT BEARING
Check the bearing rotation condition and check for abnormal noise.
If the bearing is worn or damaged, replace the steering pinion assembly.
5. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, press out the oil seal from the pinion bearing adjusting screw.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)





b. Coat a new oil seal lip with molybdenum disulfide lithium base grease.
c. Using SST press in the oil seal until it surface is flush with the pinion bearing adjusting screw.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)

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

REASSEMBLY

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

1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE





2. INSTALL STEERING RACK
a. Install the rack into the rack housing.

NOTICE: Install the rack to the steering pinion housing side of the rack housing as shown.

b. Set the rack notched side so that the pinion can be positioned inside.





3. INSTALL STEERING PINION ASSEMBLY
a. Line up the cutout portion of the steering rack with the pinion assembly.
b. Install the pinion assembly into the rack housing.

HINT:
^ Ensure that the pinion end is securely located in the bearing of the rack housing.
^ Do not engage the pinion teeth with the rack teeth.





4. INSTALL PINION BEARING ADJUSTING SCREW
a. Apply sealant to 2 or 3 threads of the screw.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the screw.
SST 09922-10010
Torque: 17 Nm (174 kgf-cm, 13 ft. lbs.)

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

HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).





5. INSTALL PINION BEARING ADJUSTING SCREW LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST to stop the pinion bearing adjusting screw, and using SST, torque the nut.
SST 09922-10010
Torque: 88 Nm (894 kgf-cm, 65 ft. lbs.)

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

HINT: Use a torque wrench with a fulcrum length of 425 mm (16.73 inch).

6. INSTALL DUST COVER
7. 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.





8. 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, while gradually loosening the rack guide spring cap, measure and adjust the preload.
SST 09612-24014 (09616-10010), 09631-10021
Preload (turning): 1.3 Nm (13 kgf-cm, 11.3 inch lbs.) or less





9. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST to stop the rack guide spring cap rotating, 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 (13.58 inch).

c. Recheck the total preload.
Preload (turning): 1.3 Nm (13 kgf-cm, 11.3 inch lbs.) or less
d. Remove the RH and LH rack ends.
10. INSTALL RACK HOUSING NO.2 BRACKET AND GROMMET
a. Align the matchmarks on the bracket and rack housing.
b. Torque the bolt.
Torque: 61 Nm (620 kgf-cm, 45 ft. lbs.)
11. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS





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

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





b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
SST 09922-10010
Torque: 61 Nm (621 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 to the rack.





12. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Install the rack boot.

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

b. Tighten a new clamp, as shown in the illustration.
13. 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: 54 Nm (550 kgf-cm, 40 ft. lbs.)

pro multis Credits:Operation CHARM About Operation CHARM