1996 TOYOTA LAND CRUISER steering

SR−34
−
STEERING POWER STEERING GEAR
1085
Author: Date:
1996 LAND CRUISER (RM451U)
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Version 1.11 - 03/16/2010

SR16M−01
−
STEERING POWER STEERING GEAR
SR−35
1996 LAND CRUISER (RM451U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR−11)
3. REMOVE STEERING WHEEL (See page SR−11)
4. REMOVE FRAME SEAL
5. REMOVE LINK JOINT PROTECTOR
Remove the 2 bolts.
6. DISCONNECT PITMAN ARM WITH RELAY ROD
(a) Remove the pitman arm set nut and spring washer.
(b) Using SST, disconnect the pitman arm from the gear as- sembly.
SST 09628−62011
7. DISCONNECT PRESSURE FEED AND RETURN TUBES
Using SST, disconnect the pressure feed and return tubes. SST 09631−22020
8. DISCONNECT SLIDING YOKE SUB−ASSEMBLY
(See page SR−13 )
9. REMOVE PS GEAR ASSEMBLY
Remove the 4 installation bolts and nuts.
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Version 1.11 - 03/16/2010

SR16N−01
SR−36
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Secure the gear assembly on SST and clamp SST in a vise. SST 09630−00014 (09631 −00142)
2. REMOVE ADJUSTING SCREW LOCK NUT AND SEAL
WASHER
3. REMOVE SIDE COVER
(a) Remove the 4 bolts.
(b) Turn the cross shaft adjusting screw clockwise until the cover comes off.
(c) Remove the O−ring from the cover.
4. REMOVE CROSS SHAFT
Using a plastic hammer, tap on the cross shaft end and pull out
the shaft.
5. REMOVE POWER PISTON PLUNGER GUIDE NUT, COMPRESSION SPRING, POWER PISTON PLUNGER
AND POWER PISTON PLUNGER GUIDE
(a) Using a hexagon wrench (10 mm), remove the plunger
guide nut.
(b) Remove the O−ring from the plunger guide nut.
6. REMOVE WORM GEAR VALVE BODY ASSEMBLY
(a) Remove the 4 bolts.
(b) Using SST, turn the valve body shaft clockwise with hold-
ing the worm gear by your finger so it cannot move.
SST 09616−00010
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Version 1.11 - 03/16/2010

−
STEERING POWER STEERING GEAR
SR−37
1996 LAND CRUISER (RM451U)
(c) Pull out the valve body assembly.
NOTICE:
Ensure that the worm gear does not come off the worm
shaft.
(d) Remove the 2 O−rings from the gear housing.
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Version 1.11 - 03/16/2010

SR16O−01
Z14503
Dial Indicator30 mm
(1.18 in.)
Z14504
Dial Indicator
Z10600
Z06211
SR−38
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the worm
gear up and down. Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance. Standard clearance: 0.03 − 0.05 (0.0012 − 0.0020 in.)
3. IF NECESSARY, ADJUST CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut. SST 09630−00014 (09631 −00051)
(c) Using a screwdriver, adjust the adjusting screw for correct thrust clearance.
(d) Using the SST, tighten a new lock nut.
(e) Using a chisel and hammer, stake the lock nut.
4. IF NECESSARY, REPLACE OIL SEAL, METAL SPACER AND TEFLON RING
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O −ring from the
gear housing.
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Version 1.11 - 03/16/2010

SR2804
−
STEERING POWER STEERING GEAR
SR−39
1996 LAND CRUISER (RM451U)
(d) Coat a new O− ring and metal spacer with power steering
fluid and install them.
(e) Using snap ring pliers, install a new snap ring.
(f) Coat a new teflon ring with power steering fluid.
(g) Form a teflon ring into a heart shape and install it with
hand.
(h) Using SST, form the teflon ring.
SST 09630−00014 (09631 −00121)
NOTICE:
The teflon ring must be squeezed before inserting the
cross shaft or damage will result.
(i) Coat a new oil seal with power steering fluid.
(j) Using SST, press in the oil seal to the gear housing. SST 09950−60010 (09951 −00340, 09951−00450)
09950 −70010 (09951 −07200)
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.
5. IF NECESSARY, REPLACE TEFLON RING AND O −
RING
(a) Using a screwdriver, remove the teflon ring and O −ring
from the worm gear valve body assembly.
NOTICE:
Be careful not to damage the worm gear valve body assem-
bly.
(b) Coat a new O −ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the teflon ring.
(d) Install the teflon ring.
(e) Coat the teflon ring with power steering fluid and snug it down with piston ring compressor for 5 − 7 minutes.
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SR−40
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
6. IF NECESSARY, REPLACE UNION SEATS
(a) Using a screw extractor, remove the 2 union seats from
the worm gear valve body assembly.
(b) Using a hammer and extension bar, tap in 2 new union seats.
NOTICE:
Before installing the union seat, remove dust sticking to
the worm gear valve body assembly.
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Version 1.11 - 03/16/2010

SR16P−01
−
STEERING POWER STEERING GEAR
SR−41
1996 LAND CRUISER (RM451U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE (See page SR−33 )
2. INSTALL WORM GEAR VALVE BODY ASSEMBLY
(a) Coat 2 new O−rings with power steering fluid and install them to the gear housing.
(b) Secure the gear housing on SST and clamp SST in vise. SST 09630−00014 (09631 −00142)
(c) Install the valve body assembly while supporting the worm gear with your fingers so that it does not rotate.
(d) Torque the 4 bolts. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
NOTICE:
Be careful not to damage the teflon ring.
(e) Using SST and a torque wrench, check the valve body as-
sembly rotating torque.
SST 09616−00010
Rotating torque:
0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf)
HINT:
Hold the worm gear to prevent it from turning.
If rotating torque is not correct, replace the worm gear valve
body assembly.
3. INSTALL POWER PISTON PLUNGER GUIDE, POWER
PISTON PLUNGER, COMPRESSION SPRING AND
POWER PISTON PLUNGER GUIDE NUT
(a) Coat a new O−ring with power steering fluid.
(b) Install the O−ring to the plunger guide nut and install the plunger guide nut with a hexagon wrench (10 mm).
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
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Brought to you by BirfMark
Version 1.11 - 03/16/2010