Disassembly/Assembly

Fig. 2 Exploded View Of Manual Steering Gear.:

Disassembly
1. Remove breather plug, then drain gear oil, Fig. 2.
2. Remove adjusting screw locknut, then the four end cover attaching nuts.
3. Rotate adjusting screw clockwise, and remove end cover.
4. Remove sector shaft, using a suitable tool.
5. Remove worm bearing adjusting screw locknut, using tool No. 09617-60010.
6. Remove worm bearing adjusting screw, using suitable tool, then remove worm shaft from gear housing. Do not disassemble ball nut from worm assembly. If found to be defective, replace entire assembly.

Inspection
1. Check worm and ball nut for wear or damage, then ensure nut rotates downshaft. Replace as necessary.
2. If necessary to replace worm bearing, on Pickup and 4Runner models, proceed as follows:
a. Remove both side bearings, using tool No. 09950-20016 or 09950-20017 or equivalent.
b. Install new bearings, using a suitable press.
c. Remove outer race from gear housing, using tool No. 09612-65014.
d. Press new outer race into housing, using tool No. 09550-10012 and a suitable press.
e. Remove outer race from adjusting screw, using tool No. 09612-65014.
f. Press in new adjusting screw outer race, using tool No. 09550-10012.
3. Remove adjusting screw oil seal, using a suitable tool, then install new oil seal, using a suitable socket.
4. Measure sector shaft trust clearance. Clearance should be .0020 inch. If clearance is not as specified, install a suitable thrust washer that will bring clearance to specifications.
5. Check sector shaft end cover for damage, then the bushing. Measure bushing I.D. 1.2598-1.2608 inch should be indicated on 1989-91 models or 1.4201 inch on 1992 models. Replace as necessary.
6. Check gear housing and bushing I.D. I.D. should be 1.2598-1.2608 inch. Replace gear housing as necessary.
7. If necessary to replace gear housing oil seal, remove seal using a suitable tool, then install new oil seal, using tool No. 09550-10012.

Assembly & Adjustment
Apply a suitable lubricant to oil seal lips, bushings and bearings prior to assembly.
1. Insert worm shaft into gear housing, Fig. 2.
2. Apply a suitable sealant to adjusting screw, then install and tighten screw.
3. Measure bearing preload, in both directions, using a suitable torque wrench. Rotate adjusting screw until preload is 3.0-4.3 inch lbs.
4. Retain adjusting screw with tool No. 09616-22010, then torque locknut with tool No. 09617-60010 to specifications. Check for proper bearing preload.
5. Install adjusting screw and thrust washer onto sector shaft, then insert sector into gear housing.
6. Place ball nut at center of worm shaft and mesh center teeth.
7. Apply a suitable sealant to new end cover gasket and end cover, then install end cover with new gasket. Loosen adjusting screw as far as possible, then torque four cover bolts to 72 ft. lbs.
8. Count total shaft rotation, then turn shaft back half number counted. With worm shaft in this position (Neutral), mark relative position between worm shaft and housing.
9. Rotate adjusting screw, using a suitable torque wrench, until preload is 6.9-9.5 inch lbs.
10. Hold adjusting screw using a suitable screwdriver, then torque locknut to specifications.
11. Align marks on sector shaft with marks on pitman arm, then ensure sector shaft has no backlash within 100° of left and right side of Neutral position.
12. Add 400cc of gear oil.