With Progressive Power Steering (PPS)

Disassembly

Fig. 47 Exploded View Of Power Steering Gear. Supra w/PPS:

1. Position rack in suitable soft jawed vise.
2. Using suitable tool, remove turn tubes and O-rings, Fig. 47.
3. Loosen tie rod end locknut, then place installation alignment marks on tie rod end and rack end, remove tie rod end.
4. Remove back boots. Do not damage rack boots or rack housing.
5. Unstake claw washers, then using suitable tool, remove rack ends, mark right and left rack ends and remove claw washers.
6. Using suitable tool, remove rack guide spring cap locknut.
7. Using suitable tool, remove rack guide spring cap.
8. Remove rack guide spring, rack guide and seat.
9. Remove rack housing gap.
10. Using suitable tool to hold control valve, remove self locking nut.
11. Remove control valve housing dust cover, place installation alignment marks on valve and rack housing, remove valve housing, valve and rack housing gasket.
12. Tap out control valve and oil seal.
13. Remove lower bearing and spacer.
14. Using suitable tool, remove snap ring, then using suitable tool, press rack until end stopper slightly touches press block, pull out rack with cylinder end stopper, two spacers and oil seal.
15. Using suitable tool, tap cylinder housing oil seal and spacer.

Inspection & Repair

1. Using suitable dial indicator, inspect rack for runout and tooth wear or damage. Maximum runout is .012 inch, if measurement is not as indicated or damaged, replace rack.
2. If required, replace rack housing oil seal and bearing.
3. If required, replace control valve housing oil seal and bearing.
4. If required, replace rack bushing oil seal, using suitable tool, remove oil seal, coat new oil seal with power steering fluid, then install.
5. If required, replace Teflon ring and O-ring as follows:
a. Remove Teflon ring and O-ring. Do not damage steering rack.
b. Coat new O-ring with power steering fluid, then install.
c. Coat new Teflon ring with power steering fluid.
d. Install Teflon ring then expand ring by hand.
e. Install expanded ring to to steering rack and snug down by hand to fit tightly in groove.
6. If required, replace control valve Teflon ring as follows:
a. Using suitable screwdriver, remove Teflon ring. Do not damage control valve.
b. Install new rings to tool No. 09631-20070 or equivalent, then expand rings.
c. Install expanded rings to control valve and snug down by hand.
d. Coat ring with power steering fluid, then carefully slide tapered end of tool No. 09631-20081 or equivalent, over rings to seat rings.
7. If required, replace hydraulic reaction chamber Teflon rings and O-rings as follows:
a. Remove Teflon ring and O-rings. Do not damage control valve.
b. Install new O-rings.
c. Expand Teflon rings by hand. Do not over expand Teflon rings.
d. Install expanded Teflon rings to control valve.
e. Coat Teflon rings with power steering fluid and snug down by hand.
f. Slide tapered end of tool No. 09631-32020 or equivalent, over Teflon rings to seat rings.
8. If required, replace pressure control valve.

Assembly
1. Coat cylinder housing oil seal lip with power steering fluid, then using suitable tool, tap in cylinder housing oil seal and spacer.
2. Install tool No. 09631-20102 equivalent to rack, scrape burrs from rack teeth end and burnish as required, coat tool with power steering fluid, the install rack to cylinder, remove tool.
3. Install cylinder end stopper, oil seal and spacers as follows:
a. Apply suitable vinyl tape to steering rack end to prevent oil seal lip damage.
b. Push oil seal into cylinder without tilting seal.
c. Install two spacers.
d. Using tool No. 09620-30010 or equivalent, drive in cylinder end stopper.
e. Using suitable snap ring pliers, install snap ring.
4. Install tool No. 09631-12070 or 09631-12071 equivalent to cylinder housing, apply 15.75 inch Hg vacuum for about 30 seconds, ensure no change in vacuum, if vacuum changes, inspect oil seal installation.
5. On 1989-91 models, remove joint L from tool No. 09631-12070 or equivalent, install L joint to cylinder end side union, apply 15.75 inch Hg vacuum for about 30 seconds, ensure no change in vacuum, if vacuum changes, inspect rack Teflon ring and O-ring installation.
6. On all models, coat Teflon rings with power steering fluid, then install control valve into housing.
7. Coat O-ring with power steering fluid and install, align valve and rack housing matchmarks, install attaching bolts and tighten to specifications.
8. Install lower bearing and spacer.
9. Using suitable tool, install new self locking nut and tighten to specifications.
10. Apply Loctite 242 or equivalent to two or three rack housing cap threads, then install cap, using suitable center punch, stake housing in two places.
11. Install rack guide seat, rack guide and spring.
12. Apply Loctite 242 or equivalent to two or three spring cap threads, then install spring cap, tighten to specifications.
13. Return rack guide spring cap 15°, turn control valve shaft right and left one or two times, loosen spring cap until rack guide compression spring is not functioning, then using suitable tool, tighten rack guide spring cap until turning preload of 7.8-10.4 ft. lbs. is indicated.
14. Apply Loctite 242 or equivalent to two or three rack guide spring cap locknut threads, then install locknut, tighten to specifications, then recheck preload as outlined in step 13.
15. Install dust cover, install claw washer and rack ends, then using suitable brass bar and hammer, stake claw washer.
16. Ensure tube hole is not clogged, then install rack boots.
17. Install tie rod ends, align matchmarks.
18. Install right and left turn pressure tubes.