1996 TOYOTA T100 power steering fluid

Downloaded from www.Manualslib.com manuals search engine SR1FE−01
R10072
Dial Indicator
R14216
SSTOil Seal SST
Bearing
W03367
SST
SST
Oil Seal
SST
R14218
SST
SST
Bearing
Oil Seal
SST
Z14493Bearing SR−60
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear or damage.
Maximum runout: 0.03 (0.0012 in.)
(b) Check the back surface for wear or damage.
2. IF NECESSARY, REPLACE OIL SEAL AND BEARING
(a) Using SST, tap out the oil seal and bearing from the con-
trol valve housing.
SST 09950−60010 (09951−00250),
09950−70010 (09951−07150)
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal.
SST 09950−60010 (09951−00180, 09951−00320,
09952−06010), 09950−70010 (09951−07200)
NOTICE:
Make sure to install the oil seal facing the correct direction.
(d) Using SST, press in a new bearing.
SST 09950−60010 (09951−00180, 09951−00340,
09952−06010), 09950−70010 (09951−07200)
3. IF NECESSARY, REPLACE 2 BEARINGS
(a) Using a brass bar, drive out the bearing from the rack
housing.

Downloaded from www.Manualslib.com manuals search engine Z14494
SST Bearing
R15250
SST
SSTBearingSST
R14219
SSTSST
Bearing
R15249
SST
Oil Seal
R14003
Press
Oil Seal
SSTSST
− STEERINGPOWER STEERING GEAR (2WD)
SR−61
1996 TOYOTA T100 (RM449U)
(b) Using SST, remove the bearing from the rack housing.
SST 09612−24014 (09613−22011)
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new bearing with molybdenum disulfide lithunm
base grease.
(d) Using SST, press in the bearing.
SST 09950−60010 (09951−00250, 09951−00310,
09952−06010), 09950−70010 (09951−07150)
(e) Coat a new bearing with molybdenum disulfide lithunm
base grease.
(f) Using SST, press in the bearing.
SST 09950−60010 (09951−00310),
09950−70010 (09951−07150)
4. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, remove the oil seal from the rack bushing.
SST 09236−00101 (09237−00010),
09612−65014 (09612−01060)
NOTICE:
As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.
Be careful not to damage the bushing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal to the rack bushing.
SST 09950−60010 (09951−00260, 09951−00410,
09952−06010)
NOTICE:
Make sure to install the oil seal facing the correct direction.

Downloaded from www.Manualslib.com manuals search engine N00399
R06172
N00401
R04603
F14898
SR−62
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
5. IF NECESSARY, REPLACE TEFLON RING AND
O−RING
(a) Using a screwdriver, remove the teflon ring and O−ring
from the steering rack.
NOTICE:
Be careful not to damage the groove of the ring.
(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 ring.
(d) Coat the ring with power steering fluid.
(e) Install the ring to the rack, and snug it down with your fin-
gers.
6. IF NECESSARY, REPLACE TEFLON RINGS
(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Install 4 new teflon rings to SST, and expand them.
SST 09631−20070
(c) Coat the rings with power steering fluid.

Downloaded from www.Manualslib.com manuals search engine SR07Y−01
F00854
SSTSST
Oil Seal
SST Vinyl Tape
W03126
Rack Teeth End
SST SR−64
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE (See page
SR−54)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950−60010 (09951−00240, 09951−00430,
09952−06010), 09950−70010 (09951−07360)
NOTICE:
Make sure to install the oil seal facing the correct
direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
HINT:
If necessary, scrape the burrs off the rack teeth end then clean
and burnish before installation.
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install SST to the rack.
SST 09631−33010
(c) Coat SST with power steering fluid.
(d) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(e) Remove the SST.

Downloaded from www.Manualslib.com manuals search engine R13021
Vinyl Tape
R15248
Wire
SST
Cylinder End
Stopper
R04609
SST
R13031
Vinyl Tape
W03369
SST
Oil Seal
− STEERINGPOWER STEERING GEAR (2WD)
SR−65
1996 TOYOTA T100 (RM449U)
4. INSTALL RACK BUSHING AND CYLINDER END
STOPPER
(a) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(b) Coat a new O−ring with power steering fluid and install it
to the bushing.
(c) Push in the bushing.
NOTICE:
Make sure to install the bushing facing the correct direc-
tion.
(d) Push in the cylinder end stopper until the wire installation
hole appears.
5. INSTALL WIRE
(a) Insert a new wire end into the hole of the rack housing.
(b) Using SST, turn the cylinder end stopper clockwise until
the wire end disappears.
SST 09631−10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631−12071
(b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(c) Install the valve assembly into the control valve housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.

Downloaded from www.Manualslib.com manuals search engine R04620
R04621
28−8°
2−5 mm
(0.08−0.20in.)
R15216
SST
Fulcrum
Length SR−70
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
17. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Make sure that the tube hole is not clogged with grease.
HINT:
If the tube hole is clogged, the pressure inside the boot will
change after it is assembled and the steering wheel turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boot.
(c) Tighten the clamp and clip, as shown in the illustration.
18. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe−in, torque the lock nut (See page
SA−7).
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Coat 2 new O−rings with power steering fluid and install
them to the tube.
(b) Using SST, install and torque the tube.
SST 09633−00020
Torque: 10 N·m (102 kgf·cm, 7 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
(c) Install the clamp plate with the bolt.

Downloaded from www.Manualslib.com manuals search engine SR07Z−01
R15251
SST
Fulcum Length
− STEERINGPOWER STEERING GEAR (2WD)
SR−71
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
Torque the 2 gear assembly set bolts and nut.
2. INSTALL MOUNT BRACKET AND GROMMET
(a) Install the grommet and mount bracket to the PS gear as-
sembly.
(b) Torque the 2 bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. CONNECT PRESSURE FEED TUBE AND INSTALL
RETRUN TUBE
(a) Coat a new O−ring with power steering fluid and install it
to the tube.
(b) Using SST, connect the pressure feed tube and install the
return tube.
SST 09631−22020
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT RETURN HOSE
5. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
6. CONNECT RH AND LH TIE ROD ENDS
Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
7. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE
(See page SR−20)
9. 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.
10. BLEED POWER STEERING SYSTEM
(See page SR−4)
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
13. INSTALL STEERING WHEEL PAD
(See page SR−20)
14. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)

Downloaded from www.Manualslib.com manuals search engine Z18651
 Washer
 O−Ring
 No.1 Lock Nut Side Cover No.1 Hose Support Bracket Adjusting Screw Lock Nut
Sector Shaft Adjusting Screw
Cross Shaft
Power Piston
Plunger Guide Nut
Compression Spring
Power Piston Plunger
Power Piston Plunger Guide
Power Steering Gear HousingNeedle Roller Bearing
 Union Seat
 O−Ring
 Teflon RingWorm Gear Valve
Body Assembly
Metal Spacer
 Snap ring
Non−reusable part
Power Steering fluid
Molybdenum disulfide lithium base grease  O−Ring
 O−Ring
 Teflon Ring
 Oil Seal
61 (620, 45)
61 (620, 45)
: Specified torque
N·m (kgf·cm, ft·lbf)
46 (470, 34)
20 (205, 15)
− STEERINGPOWER STEERING GEAR (4WD)
SR−73
1747 Author: Date:
1996 TOYOTA T100 (RM449U)