Disassembly and Assembly

Fig. 15 Exploded View Of Power Steering Gear. Cressida:

Disassembly
1. Connect a suitable holding fixture to gear housing, then place fixture in a suitable vise, Fig. 15.
2. Remove right and left turn pressure tubes, using tool No. 09633-0020.
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 outboard rack boots.
5. Unstake claw washer, then remove rack ends. Mark left and right ends respectively, then remove claw washers and inboard rack boot.
6. Loosen locknut, then remove steering damper support bracket. Locknut has lefthand threads.
7. Remove rack guide spring cap locknut, then the rack guide spring cap.
8. Remove rack guide spring, then the rack guide and seat.
9. Remove two attaching bolts, then the solenoid valve. Remove O-rings from solenoid valve and rack housing.
10. Mark relative position between control 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 cylinder end stopper nut, using tool No. 09631-20090.
12. Using tool No. 09612-10093 and a suitable press, remove rack and oil seal. Pull out steering rack with oil seal and rack end guide from cylinder.
13. Remove dust cover, then the bearing guide nut. Remove O-ring from bearing guide nut.
14. Tap out control valve, using a suitable mallet.

Inspection & Repair
1. Inspect rack for runout, tooth wear and damage and replace as necessary. Maximum runout should be .006 inch on 1989 models or .012 inch on 1990-92 models.
2. Check needle roller bearing in cylinder housing for wear or damage. If bearing is defective, replace cylinder housing assembly.
3. If necessary to replace control valve bearing oil seal, press out oil seal and bearing, using tool Nos. 09631-12020 and 09630-24013. Press in new oil seal and bearing using tool Nos. 09631-12020 and 09630-24013 and a suitable press.
4. If necessary to replace cylinder housing oil seal, drive out spacer and oil seal, using tool Nos. 09631-12020, and 09631-22040, then install new spacer and oil seal, using tool Nos. 09631-12020 and 09631-12040.
5. If necessary to replace bearing locknut oil seal, press out old oil seal, using a suitable tool, then install new oil seal using No. 09631-20040.
6. If necessary to replace Teflon ring and O-ring, remove them then install new O-ring. Expand Teflon ring, then install onto rack. Apply a suitable lubricant to rings.
7. If necessary to replace control valve Teflon ring, proceed as follows:
a. Remove ring, using a suitable tool.
b. Place new ring onto tool No. 09631-20070 to expand it.
c. Install rings onto control valve, then ensure proper installation position.
d. Apply a suitable lubricant to Teflon ring, then slide tapered end of tool over ring and seat ring.
8. If necessary to replace union seat, remove it, using a 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. 09631-20102 onto rack, then apply a suitable lubricant. Insert rack into cylinder, then remove tool.
2. Insert rack end guide into housing. Wrap vinyl tape around steering rack end, then apply a suitable lubricant. Install oil seal and end stopper, pushing seal into cylinder and coating stopper threads with Loctite 242 or equivalent.
3. Torque end stopper nut to specifications. Stake end stopper nut and housing using a suitable punch.
4. Ensure cylinder is air tight. Connect tool No. 09631-22030 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 to guide nut. Install bearing guide nut, then tighten to specifications. Stake nut in place, then install dust cover.
7. Install new O-ring to control valve housing, then align match marks on valve housing and rack housing. Insert two attaching bolts and tighten to specifications.
8. Assemble new O-rings to solenoid valve and ring housing, then install solenoid valve and tighten attaching bolts to specifications.
9. Install rack guide seat, rack guide and 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 30°, 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 4.3-8.7 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 preload, then stake spring cap and locknut.
13. Install steering damper support bracket onto rack end, then install inboard boot onto cylinder end.
14. Install new claw washer and rack end, then align claw with rack groove and tighten rack end to specifications. Stake claw washer, using a hammer and suitable drift.
15. Adjust support bracket installation surface at right angle to the upper flat face of the gear housing side mounting position as follows:
a. Place gear housing onto two prisms on stool, then set mounted face of gear housing parallel to stool.
b. Using a suitable square, check and adjust damper support bracket at right angle, then lightly tighten locknut.
c. Mark relative position between damper support bracket and rack end.
d. Using tool Nos. 09617-14010 and 09631-22050, tighten locknut to specifications.
e. Recheck support angle.
f. Stake locknut, using a hammer and suitable chisel.
16. Stake claw washers, then install rack boots, clamps and clips. Ensure open end of clips face outward.
17. Screw locknuts and tie rods ends onto rack ends until match marks are aligned.
18. Adjust toe-in, then tighten locknuts to specifications.
19. Install right and left turn tubes, then tighten fittings to specifications.
20. Install union bolts over new gaskets, then tighten to specifications.