Part 1

RACK & PINION POWER STEERING GEAR ASSY
OVERHAUL

NOTICE: When installing, coat the parts indicated by arrows with power steering fluid, MP grease, silicon grease or molybdenum disulfide lithium base grease.

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD





2. SEPARATE STEERING INTERMEDIATE SHAFT ASSY
a. Fix the steering wheel with the seat belt in order to prevent rotation.

HINT: This operation is useful to prevent damage to the spiral cable.





b. Loosen bolt A and remove the clamp from the hole cover No.1.
c. Separate the hole cover No.2 from the hole cover No.1.
d. Loosen bolt B.





e. Put matchmarks on the steering intermediate shaft assy and the power steering gear assy. Remove the bolt and disengage the intermediate shaft assy.
3. REMOVE FRONT WHEEL
4. SEPARATE TIE ROD ASSY LH
SST 09628-62011
5. SEPARATE TIE ROD ASSY RH
SST 09628-62011

HINT: Perform the same procedure as for the LH.

6. SEPARATE FRONT STABILIZER LINK ASSY LH

HINT: Separate the upper side of the stabilizer link assy.

7. SEPARATE FRONT STABILIZER LINK ASSY RH

HINT:
^ Perform the same procedure as for the LH.
^ Separate the upper side of the stabilizer link assy.





8. REMOVE FRONT STABILIZER BRACKET NO.1 LH
a. Remove the 2 bolts, the stabilizer bracket No.1 LH and the stabilizer bar bush No.1.
9. REMOVE FRONT STABILIZER BRACKET NO.1 RH

HINT: Perform the same procedure as for the LH.





10. DISCONNECT PRESSURE FEED TUBE ASSY
a. Using SST, disconnect the return tube assy from the power steering gear assy.
SST 09023-12700





b. Using SST, disconnect the pressure feed tube assy from the power steering gear assy.
SST 09023-12700





c. 2AZ-FE: Remove the nut and separate the tube clamp.
d. 3MZ-FE: Remove the nut and separate the tube clamp and the heat insulator.





e. Remove the bolt and separate the tube clamp.
11. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR (3MZ-FE ENGINE TYPE)

NOTICE: Be careful not to damage the heat insulator.





12. REMOVE RACK & PINION POWER STEERING GEAR ASSY
a. Remove the 2 bolts, nuts and the power steering gear assy.





13. REMOVE STEERING LEFT TURN PRESSURE TUBE
a. Using SST, disconnect the left turn pressure tube.
SST 09023-38200
b. Remove the 2 O-rings from the left turn pressure tube.
14. REMOVE STEERING RIGHT TURN PRESSURE TUBE
SST 09023-38200

HINT: Perform the same procedure as for the another side.





15. FIX RACK & PINION POWER STEERING GEAR ASSY
a. Using SST, secure the power steering gear assy.
SST 09612-00012

HINT: Wrap the SST with tape before use, in order to prevent damaging the power steering gear assy.





16. REMOVE TIE ROD ASSY LH
a. Put matchmarks on the tie rod assy LH and the rack end.
b. Loosen the lock nut and remove the tie rod assy LH and the lock nut.
17. REMOVE TIE ROD ASSY RH

HINT: Perform the same procedure as for the LH.

18. REMOVE STEERING RACK BOOT CLIP
a. Remove the 2 boot clips.
19. REMOVE STEERING RACK BOOT NO.2 CLAMP
a. Using pliers, remove the rack boot No.2 clamp.

NOTICE: Be careful not to damage the boot.

20. REMOVE STEERING RACK BOOT NO.1 CLAMP

HINT: Perform the same procedure as for the No.2 clamp.

NOTICE: Be careful not to damage the boot.

21. REMOVE STEERING RACK BOOT NO.2
22. REMOVE STEERING RACK BOOT NO.1





23. REMOVE STEERING RACK END SUB-ASSY
a. Using a screwdriver and a hammer, unstake the claw washer.

NOTICE: Avoid any impact to the power steering rack.





b. Using SST, remove the steering rack end sub-assy and the claw washer.
SST 09922-10010

NOTICE: Use SST 09922-10010, following the direction shown in the illustration.





24. REMOVE RACK GUIDE
a. Using SST, remove the spring cap lock nut.
SST 09922-10010

NOTICE: Use SST 09922-10010, following the direction shown in the illustration.





b. Using SST, remove the rack guide spring cap.
SST 09631-10021
c. Remove the compression spring and the rack guide.





25. REMOVE POWER STEERING CONTROL VALVE
a. Using a socket wrench (27 mm), remove the rack housing cap.





b. Using SST, hold the control valve shaft and remove the nut.
SST 09616-00011





c. Wrap vinyl tape around the spline of the control valve in order to prevent damaging the oil seal.
d. Remove the dust cover from the control valve housing.





e. Remove the 2 bolts and the control valve housing together with the control valve.
f. Remove the gasket.





g. Using a plastic hammer, remove the control valve.
h. Remove the oil seal from the control valve.





i. Using a screwdriver, remove the 4 control valve spacers.

NOTICE: Be careful not to damage the spacer grooves.





26. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Using SST and a press, remove the control valve upper bearing and the upper oil seal from the control valve housing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)





27. REMOVE CYLINDER END STOPPER
a. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
b. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and the cylinder end stopper.
28. REMOVE POWER STEERING RACK
a. Remove the steering rack from the rack housing.





29. REMOVE POWER STEERING RACK BUSH
a. Remove the rack bush with the rack bush oil seal from the steering rack.
b. Using SST, remove the rack bush oil seal from the rack bush.
SST 09527-21011, 09612-24014 (09613-22011)

NOTICE: Be careful not to drop the rack bush.

c. Using a screwdriver, remove the O-ring from the rack bush.





30. INSPECT POWER STEERING RACK
a. Using a dial indicator, check for runout of the steering rack and teeth wear.
Maximum runout: 0.3 mm (0.0118 inch)
If runout exceeds maximum, replace the power steering gear assy.
b. Check the rack surface for wear and damage.
If necessary, replace the power steering gear assy.





31. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
a. Using SST and a press, remove the cylinder tube oil seal.
SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)

NOTICE: Be careful not to damage the inside surface of the rack housing.





32. REMOVE POWER PISTON OIL SEAL
a. Using a screwdriver, remove the oil seal and the O-ring.

NOTICE: Be careful not to damage the oil seal groove.





33. INSTALL POWER PISTON OIL SEAL
a. Coat a new O-ring with power steering fluid and install it to the steering rack.
b. Expand a new oil seal with your fingers.

NOTICE: Be careful not to overly expand the oil seal.

c. Coat the oil seal with power steering fluid.





d. Install the oil seal to the steering rack, and adjust with your fingers.





34. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
a. Coat a new cylinder tube oil seal lip with power steering fluid.
b. Using SST and a press, install the cylinder tube oil seal.
SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360)

NOTICE: Make sure that the oil seal is installed in the correct direction.





35. INSPECT TIE ROD ASSY LH
a. Secure the tie rod assy LH in a vise.
b. Install the nut to the stud bolt.
c. Flip the ball joint back and forth 5 times or more.
d. Using a torx wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn.
Turning torque: 0.98 to 3.92 Nm (10.0 to 40.0 kgf-cm, 8.7 to 34.7 inch lbs.)
If turning torque is not as specified, replace the tie rod assy LH.
36. INSPECT TIE ROD ASSY RH

HINT: Perform the same procedure as for the LH.





37. INSTALL POWER STEERING RACK
a. Apply grease to the rack teeth ends.
b. Affix SST to the steering rack.
SST 09631-33010

HINT: If necessary, scrape the burrs off the rack teeth ends and burnish.

c. Coat SST and the power piston oil seal with power steering fluid.
d. Install the steering rack to the rack housing.
e. Remove SST.





38. INSTALL POWER STEERING RACK BUSH
a. Coat a new rack bush oil seal lip with power steering fluid.
b. Using SST and a press, install the rack bush oil seal to the rack bush.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

NOTICE: Make sure that the oil seal is installed correctly.

c. Coat a new O-ring with power steering fluid and install it to the rack bush.





d. Install the rack bush to the rack housing.

HINT: Wrap vinyl tape around the end of the steering rack in order to prevent damaging the rack bush oil seal.





39. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
b. Install a new wire into the cylinder end stopper.
c. Using a screwdriver, turn the cylinder end stopper counterclockwise by 450° ± 50°.