Disassembly and Assembly

Fig. 12 Rack & pinion manual steering gear assembly. 1984-85 Celica & 1984-88 Corolla RWD (Tercel & Starlet similar):

Disassembly

1. Place steering assembly in suitable vise, then mark position of tie rod and rack end for reference during assembly. Remove tie rod ends, Fig. 12.
2. Remove clip and clamp, then remove rack boot.
3. Remove rack end dust seal, then remove claw washer. Remove rack end using suitable tool and a wrench. Use caution not to scratch outside of rack with wrench.
4. Remove rack guide spring cap locknut, rack guide spring cap and spring.
5. Remove rack guide, dust cover, locknut and pinion bearing adjusting screw.
6. Pull rack from rack housing side and align rack notched portion with pinion. Remove pinion, upper bearing and washer.
7. Remove rack from pinion side, using caution not to rotate rack as it is being removed.

Inspection & Assemble

1. Inspect rack boot, rack end dust seal and rack clamp for damage and wear.
2. Check for excessive play in rack end ball joint.
3. Inspect rack guide for damage or wear.
4. Inspect pinion tooth surface for damage or wear. Check oil seal and dust cover for damage or wear.
5. If pinion oil seal is to be replaced, install new oil seal until it protrudes .02 inch (.5 mm) from pinion bearing adjusting screw tip.
6. To replace pinion upper bearing, remove and install using suitable puller and press. Check to ensure spacer is installed before installing bearing.
7. To replace lower bearing, heat rack housing to 175°F, then tap bearing from shaft. Heat housing again when installing bearing.
8. Measure rack runout using dial indicator. Runout should be no more than .012 inch (.3 mm).
9. Apply suitable grease to pinion lower bearing, and rack bushing. Fill 1/2 of rack housing with grease. Install rack into rack housing. Position rack notched area so that pinion can be installed.
10. Apply grease to pinion bearing and tooth surfaces, then install pinion and spacer.
11. Install pinion bearing adjusting screw and adjust preload to 3.5 inch lbs. (4 kg-cm) on 1982-86 Tercel, 1982-86 Corolla RWD, and to 3.2 inch lbs. (3.7 kg-cm) on 1982-85 Celica, 1982-84 Starlet and all 1987-88 vehicles. Loosen adjusting screw until preload is 1.7-2.6 inch lbs. (2-3 kg-cm) on 1982-86 Tercel, 1982-86 Corolla RWD, or 2-2.9 inch lbs. (2.3-3.3 kg-cm) on 1982-85 Celica, 1982-84 Starlet and all 1987-88 vehicles.
12. Install adjusting screw locknut and torque to 83 ft. lbs. (113 Nm). Check for pinion preload of 1.3-2.2 inch lbs. (1.5-2.5 kg-cm) on 1982-86 Tercel, 1982-84 Starlet, 1987-88 Tercel Wagon, or 2.0-2.9 inch lbs. (2.3-3.3 kg-cm) on 1982-85 Celica, 1982-88 Corolla RWD and 1987-88 Tercel Sedan.
13. Apply grease to rack guide, then install spring and rack guide spring cap. Torque spring cap to 18 ft. lbs. (2.5 kg-m) on all except 1987-88 Tercel Sedan, or 43 ft. lbs. on 1987-88 Tercel Sedan. Back off cap 90° on 1982-85 Celica, 1982-86 Tercel and 1987-88 Tercel Wagon, 25° on Starlet and 1987-88 Corolla RWD models, or 12° for 1982-86 Corolla RWD. Check for preload of 4.3-11.3 inch lbs. (5-13 kg-cm) on 1982-86 Tercel, 6.1-7.8 inch lbs. (7-9 kg-cm) on Starlet models, 8.7-11 inch lbs. on 1982-85 Celica and 1987-88 Tercel Wagon, 6.5-8.2 inch lbs. for 1982-88 Corolla RWD, and 5.2-12.2 inch lbs. for 1987-88 Tercel Sedan. Adjust by rotating spring cap.
14. Install locknut and torque to 51 ft. lbs. on all models except 1987-88 Tercel Sedan, or 43 ft. lbs. on 1987-88 Tercel Sedan. Recheck preload as described in step 13.
15. Install dust cover and claw washer, aligning claw on washer with rack groove, then torque rack end to 76 ft. lbs. on 1982-85 Celica, 61 ft. lbs. on all models except Celica and 1987-88 Tercel Sedan, or 43 ft. lbs. on 1987-88 Tercel Sedan. Stake claw washer in position
16. Install rack end seal and dust boot. Check to ensure that tube hole is not blocked.
17. Install rack boot clamp with tapered edge toward tube side. Install rack boot clip.
18. On Starlet and 1982-86 Tercel models only, check that steering rack stroke is as follows: Starlet, 4.8 inches (122 mm); Tercel, 5.283 inches (134.2 mm). Check that boots do not bend or twist during stroke.
19. Install tie rod end aligning marks made during disassembly.