Page 1289 of 1399
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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Page 1294 of 1399
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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Page 1295 of 1399
SR−42
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
4. DETERMINE CENTER POSITION
(a) Using SST, turn the worm gear valve body shaft so full
lock in both directions and determine the exact center.
SST 09616−00010
(b) Place matchmarks on the worm gear valve body shaft and
worm gear valve body housing to show neutral position.
5. INSTALL CROSS SHAFT AND SIDE COVER
(a) Coat a new O −ring with power steering fluid and install it
on the side cover.
(b) Assemble the cross shaft to the side cover.
HINT:
Fully loosen the cross shaft adjusting screw.
(c) Install and push the cross shaft into the gear housing so that the center teeth mesh together.
(d) Torque the 4 bolts in a diagonal pattern. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
6. ADJUST TOTAL PRELOAD
(a) Install SST with a torque wrench on the worm gear valve body shaft.
SST 09616−00010
(b) Turn the cross shaft adjusting screw until the preload is
within specification.
Preload (Turning):
0.74 − 10.8 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf)
7. INSTALL NEW SEAL WASHER
8. INSTALL ADJUSTING SCREW LOCK NUT
Torque the lock nut while holding the cross shaft adjusting
screw. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
9. CHECK TOTAL PRELOAD
Using SST and a torque wrench, check total preload. SST 09616−00010
Total preload (Turning):
0.74 − 1.08 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf)
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Page 1296 of 1399
SR16Q−01
SR2922
Alignment Marks
−
STEERING POWER STEERING GEAR
SR−43
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque the 4 installation bolts and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT SLIDING YOKE SUB−ASSEMBLY (See page SR−19 )
3. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the pressure feed and return tubes. SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM WITH RELAY ROD
(a) Align the alignment marks on the cross shaft and pitman arm and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE (See page SR−19 )
7. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
8. BLEED POWER STEERING SYSTEM
(See page SR−3 )
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
11. INSTALL STEERING WHEEL PAD (See page SR−19)
12. CHECK FRONT WHEEL ALIGNMENT (See page SR−4 )
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Page 1298 of 1399
SR16S−03
SR4102
SST
SR4103
SST
SR4104
SST
−
STEERING STEERING LINKAGE
SR−45
1996 LAND CRUISER (RM451U)
REMOVAL
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE ENGINE UNDER COVER
Remove the 4 bolts.
2. REMOVE PITMAN ARM
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the pitman arm from the relay rod
assembly.
SST 09611 −22012
(c) Remove the pitman arm set nut and spring washer.
(d) Using SST, disconnect the pitman arm from the PS gear assembly.
SST 09628−62011
3. REMOVE STEERING DAMPER WITH STEERING DAMPER BRACKET
(a) Remove the nut and 2 damper bracket set bolts.
(b) Using SST, disconnect the damper with damper bracket from the relay rod assembly.
SST 09611 −22012
4. REMOVE STEERING DAMPER
(a) Secure the damper bracket in a vise.
(b) Remove the nut.
(c) Using SST, r emove the damper from the damper bracket.
SST 09610−55012
5. REMOVE RELAY ROD ASSEMBLY
(a) Remove the cotter pin and nut.
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Page 1300 of 1399
SR16T−01
−
STEERING STEERING LINKAGE
SR−47
1996 LAND CRUISER (RM451U)
INSTALLATION
HINT:
When connecting the ball stud to the arm or rod, remove the
grease on the joint surfaces.
1. INSTALL TIE ROD ENDS AND RELAY ROD ENDS
(a) Turn the tie rod ends or relay rod ends equal amounts into
the rod tube. Tie rod assembly should be approximately
1,233 mm (48.54 in.). Relay rod assembly should be
approximately 1,090 mm (42.91 in.).
(b) The remaining length of threads on both tie rod ends or relay rod ends should be equal.
(c) Temporarily tighten the tie rod end or relay rod end clamps.
2. INSTALL TIE ROD ASSEMBLY
(a) Connect the tie rod assembly to the RH and LH knuckle arms.
(b) Torque the 2 nuts. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf)
(c) Install 2 new cotter pins.
(d) After adjusting toe−in, torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
3. INSTALL RELAY ROD ASSEMBLY
(a) Connect the relay rod assembly to the knuckle arm.
(b) Torque the nut. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf)
(c) Install a new cotter pin.
(d) Torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
4. INSTALL STEERING DAMPER
(a) Secure the damper bracket in a vise.
(b) Connect the damper to the damper bracket.
(c) Torque a new nut. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
5. INSTALL STEERING DAMPER WITH STEERING DAMPER BRACKET
(a) Connect the damper with damper bracket to the relay rod
assembly.
(b) Torque a new nut and 2 damper bracket set bolts.
Torque:
Nut: 74 N·m (750 kgf·cm, 54 ft·lbf)
Bolt: 39 N·m (400 kgf·cm, 29 ft·lbf)
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Page 1301 of 1399
SR2922
Alignment Marks
SR−48
−
STEERING STEERING LINKAGE
1996 LAND CRUISER (RM451U)
6. INSTALL PITMAN ARM
(a) Align the alignment marks on the pitman arm and the
cross shaft, and install the spring washer and set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
(b) Connect the pitman arm to the relay rod assembly.
(c) Torque the nut. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf)
(d) Install a new cotter pin.
7. INSTALL ENGINE UNDER COVER
Tighten the 4 bolts.
8. CHECK FRONT WHEEL ALIGNMENT (See page SA−4 )
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SS00F−01
V06821
MarkMark
Class
Class
Hexagon head
bolt Bolt
head No.4−
5−
6−
7−
8−
9−
10−
11 − 4T
5T 6T
7T 8T
9T
10T 11 T
No mark
No mark
Hexagon
flange bolt
w/ washer
hexagon bolt 4T
4T
5T
6T
7T
8T
Hexagon
head
bolt
Hexagon
flange bolt w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt 2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
lines Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange boltw/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt 4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved
9T
10T 11 T
4T
6T
4T
−
SERVICE SPECIFICATIONS STANDARD BOLT
SS−1
124
Author: Date:
1996 LAND CRUISER (RM451U)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
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