Disassembly and Assembly

Disassembly

Fig. 50 Exploded View Of Power Steering Gear. Paseo & Tercel:

1. Place steering gear in suitable vice, then remove pressure lines using suitable tool, Fig. 50.
2. Remove the air control valve.
3. Mark position of tie-rod and rack end for reference during assembly, then remove tie-rods.
4. Remove rack boots, then unstake claw washer.
5. Using suitable tool, remove rack ends, then the claw washer.
6. Using suitable tool, remove rack guide spring cap locknut.
7. Remove rack guide spring cap, using suitable tool.
8. Remove rack guide spring, rack guide and rack housing cap.
9. Using suitable tool, remove self locking nut.
10. Remove control valve dust cover, then the snap ring. Using suitable tool, remove the control valve with oil seal and bearing, then the oil seal from the control valve.
11. Using suitable tool, remove upper bearing from the control valve.
12. Using suitable tool, turn the cylinder end stopper clockwise until the wire end comes out of the opening, then turn the cylinder and stopper counter-clockwise and remove wire, then pull out cylinder end stopper.
13. Remove rack bushing and rack, then the cylinder side oil seal and spacer.

Inspection & Repair
1. Check rack for damage, wear or excessive runout. If runout exceeds .012 inch, replace rack assembly.
2. If necessary replace cylinder control valve lower bearing and oil seal as follows:
a. Drive out bearing, then using suitable tool, remove oil seal. Using suitable tool, install new oil seal.
b. Install new bearing with rack housing cap, tighten cap to specifications, then remove rack housing cap.
3. If necessary, replace rack bushing oil seal by prying out the oil seal, then using a 24mm socket wrench, drive in a new oil seal.
4. If necessary, replace rack Teflon ring and O-ring, coating Teflon ring with power steering fluid.
5. If necessary, replace control valve Teflon ring as follows:
a. Pry off Teflon ring with suitable tool.
b. Install Teflon ring onto suitable tool, then install Teflon rings to control valve and snug down with fingers.
c. Coat ring with power steering fluid, then slide tapered end of tool over the Teflon ring to seat ring.
6. If necessary, remove control valve housing union seat with suitable screw extractor. Drive new seat fully into position using an extension bar and hammer.

Assembly
During assembly, coat all moving parts, bearings and bushings with molybdenum disulfide lithium base grease, and all O-rings and Teflon rings with power steering fluid.
1. Install rack housing cylinder side oil seal and spacer by coating new oil seal with power steering fluid, then install oil seal and spacer to suitable tool, and drive into cylinder.
2. Install suitable tool onto rack assembly, coat tool with power steering fluid, then remove tool.
3. Install new O-ring onto the rack bushing, then install rack bushing in the rack cylinder.
4. Push cylinder end stopper into rack cylinder until wire installation hole appears. Insert a new wire end into hole, then using suitable tool, turn cylinder end stopper clockwise until wire end disappears.
5. Ensure cylinder is air tight. Connect suitable tool, to union of cylinder housing, then apply 15.75 inches Hg vacuum for at least 30 seconds. There should be no drop in vacuum.
6. Install control valve assembly as follows:
a. Push control valve into housing.
b. Using suitable tool, press in the upper bearing.
c. Using suitable tool press in oil seal until snug with bearing.
d. Install snap ring, then dust cover.
7. Using suitable tool, install self-locknut into lower control valve housing. Torque nut to specifications.
8. Apply Loctite 242 or equivalent to rack housing cap, then install cap, tighten to specifications. Using a center punch, stake the housing cap at opposite ends of cap.
9. Install rack guide and rack guide spring.
10. Adjust total preload as follows:
a. Apply Loctite 242 or equivalent, to spring cap, then using suitable tool, install into housing, tighten cap to specifications.
b. Turn the spring cap counter clockwise 12°, then rotate control valve shaft right then left twice.
c. Loosen the spring cap until rack guide compression spring is not functioning.
d. Using tool No. 09616-00010 with torque wrench on control valve shaft, turn spring cap until preload of 6.9-11.3 inch lbs. on 1989 models or 7.8-13.0 inch lbs. on 1990-92 models is obtained.
11. Apply Loctite 242 or equivalent, to spring cap locknut, then install locknut and tighten specifications. Recheck preload as specified in previous step.
12. Install new rack end claw washers, then rack ends. Torque rack ends to specifications.
13. Stake claw washers into position, then ensuring that tube hole is not clogged with grease, install rack boots, clamps and clips. Ensure clip ends face outward.
14. Install tie-rod ends, ensuring marks made during disassembly are aligned. After adjusting toe-in, tighten locknuts to specifications.
15. Install new pressure line O-rings, then the pressure lines. Torque to specifications.
16. Install air control valve. Tighten to specifications.