Disassembly and Assembly

Fig. 7 Exploded View Of Rack & Pinion Power Steering Gear. Celica:

Disassembly
1. Connect a suitable holding fixture to gear housing, then place fixture in a suitable vise, Fig. 7.
2. Remove air control valve, then the right and left pressure tubes.
3. Loosen locknut, then mark relative position between tie rod end and rack end. Remove tie rod end and locknut.
4. Remove rack boots clips and clamps, then the rack boots.
5. Unstake claw washer, then remove rack ends. Mark left and right ends respectively, then remove claw washers.
6. Remove rack guide spring cap locknut, then the rack guide spring cap.
7. Remove rack guide spring, then the rack guide and seat.
8. Remove bearing guide locknut, then the bearing guide nut.
9. Remove dust cover.
10. Mark relative position between valve housing and rack housing, then remove two retaining bolts. Pull out valve with valve housing, then remove O-ring from rack housing.
11. Remove spool valve spring seat and spring, then the control valve with bearing.
12. Remove snap ring from end stopper, then press out cylinder end stopper until end stopper slightly touches press block.
13. Pull out rack together with cylinder end stopper, spacer and oil seal.

Inspection & Repair
1. Inspect rack for excessive runout, tooth wear, or damage and replace as necessary. Maximum runout should be .012 inch.
2. If necessary to replace cylinder housing oil seal, drive out spacer and oil seal, then install new spacer and oil seal.
3. If necessary, to replace rack housing oil seal, pry out oil seal, using a suitable tool, then install new seal.
4. If necessary to replace control valve housing oil seal, proceed as follows:
a. Press out oil seal with bearing.
b. Press in new oil seal.
5. If necessary to replace Teflon ring and O-ring, proceed as follows:
a. Remove Teflon ring and O-ring.
b. Install new Teflon ring onto suitable tool to expand it.
c. Insert tool with ring onto rack, then install ring onto piston.
d. Apply a suitable lubricant to Teflon ring, then ensure proper installation position.
6. If necessary to replace control valve Teflon ring, proceed as follows:
a. Remove ring, using a suitable tool.
b. Place new ring onto suitable tool to expand it.
c. Install rings onto control arm, then ensure proper installation position.
d. Apply a suitable lubricant to Teflon ring, then slide tapered end of tool over ring and seat ring.
7. If necessary to replace union seat, remove it with suitable screw extractor, then tap new union seat into place, using a hammer and suitable drift.

Assembly
During assembly, coat all moving parts, bearings, and bushings with molybdenum disulfide lithium based grease, and all O-rings and Teflon rings with power steering fluid.
1. Install tool No. 09631-20100 onto rack, then apply a suitable lubricant. Insert rack into cylinder, then remove tool.
2. Wrap vinyl tape around steering rack end, then apply a suitable lubricant. Install oil seal, pushing seal into cylinder.
3. Install spacer and cylinder end stopper, then seat components, using tool No. 09612-22011. Install snap ring.
4. Ensure cylinder is air tight. Connect tool No. 09631-12070 to union of cylinder housing, then apply 15.75 inches Hg vacuum for approximately 30 seconds. There should be no drop in vacuum.
5. Apply a suitable lubricant to Teflon ring, then insert control valve into housing.
6. Apply a suitable lubricant, then install O-ring, spring and spring seat.
7. Align match marks on valve housing and rack housing, then insert two attaching bolts and tighten specifications.
8. Install control valve lower bearing, then apply a suitable sealant to 2 or 3 threads of bearing guide nut. Install nut, then tighten to specifications. Using a suitable torque meter, loosen guide nut until preload of 3.9-5.6 inch lbs. is obtained.
9. Apply Loctite 242 or equivalent to 2 or 3 threads of bearing guide locknut, then install locknut and tighten to specifications. Install rack guide seat, rack guide, then the rack guide spring.
10. Apply a suitable sealant to 2 or 3 threads of spring cap, then tighten cap to specifications.
11. Adjust total preload as follows:
a. Back off spring cap 15°, then rotate control valve shaft right and left two to three times.
b. Loosen spring cap until rack guide compression spring is not functional.
c. Tighten rack guide spring cap until preload of 7.8-10.4 inch lbs. is obtained.
12. Apply a suitable sealant to 2 or 3 threads of locknut, then install rack guide spring cap locknut and tighten to specifications. Recheck total preload.
13. Install new claw washer and rack end, then tighten rack end specifications. Stake claw washer, using a hammer and suitable drift.
14. Install rack boots, clamps and clips, ensuring holes in tube are not clogged, and that clip ends face outward.
15. Screw locknuts and tie rod ends onto rack ends until match marks are aligned.
16. Install new union seats. Install right and left turn tubes, then tighten fittings to specifications.