Page 1773 of 2062
Downloaded from www.Manualslib.com manuals search engine R04613
SST
R05209
SR−66
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
9. INSTALL CONTROL VALVE HOUSING WITH CON-
TROL VALVE ASSEMBLY
(a) Place a new gasket on the rack housing.
(b) Torque the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
10. INSTALL DUST COVER
11. INSTALL SELF−LOCKING NUT
Using SST to stop the control valve assembly, install a new self−
locking nut.
SST 09616−00010
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
12. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the rack housing cap.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a center punch, stake the cap at 2 places.
13. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING CAP
(a) Apply sealant to 2 or 3 threads of the spring cap.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Temporarily install the spring cap.
14. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporariry install the RH and LH rack ends.
(b) Set the steering rack at the rack stroke center.
(c) Fix the steering gear in a vise so that the rack guide spring
cap faces straight up.
(d) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
Page 1775 of 2062
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Steering Twist of Steering Rack
Steering Rack Center Position
Dial Indicator
0.08mm(0.0032in.) or less (55kgf·cm, 4.8in.·lbf)
SST
Torque
Wrench
Fulcrum
LengthSST 90°
180°Value Control Rack Dial Indicator
Shaft SST Clockwise Counterclckwise
90°
180° 5.4N·m SR−68
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
(h) Using a hexagon wrench (21 mm), gradually tighten the
rack guide spring cap and adjust the twist of the steering
rack to 0.08 mm (0.0032 in.) or less when the rack is
twisted clockwise and counterclockwise by SST and
torque wrench with 5.4 N·m (55 kgf·cm, 48 in.·lbf) of
torque applied.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion
HINT:
Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
(i) Using SST to ratate the control valve shaft, adjust the
twist of the rack so that it is within the above specifications
at the following 5 points:
SST 09616−00010
(1) Steering rack at center position.
(2) Steering pinion shaft rotated 90° clockwise from the
center position.
(3) Steering pinion shaft rotated 90° counterclockwise
from the center position.
(4) Steering pinion shaft rotated 180° clockwise from
the center position.
(5) Steering pinion shaft rotated 180° counterclock-
wise from the center position.
Page 1776 of 2062
Downloaded from www.Manualslib.com manuals search engine R14224
Fulcrum
Length
SST
Hexagon Wrench
R14225
SST
Z14297
SST
Length Fulcrum
R04619
− STEERINGPOWER STEERING GEAR (2WD)
SR−69
1996 TOYOTA T100 (RM449U)
(j) Apply sealant to 2 or 3 threads of the rack guide spring
cap lock nut.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(k) Using a hexagon wrench (21 mm) to hold the rack guide
spring cap, and using SST, install and torque the lock nut.
SST 09922−10010
Torque: 51 N·m (521 kgf·cm, 38 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(l) Repeat (h)
15. CHECK TOTAL PRELOAD
(a) Using SST and a torque wrench, check the total preload.
SST 09616−00010
Preload (turning):
0.5 − 1.4 N·m (5 − 14 kgf·cm, 4.3 − 12.2 in.·lbf)
HINT:
The total preload must be within the specification throughout
the full stroke of the steering rack.
If it is not within specification, adjust the total preload again.
(b) Remove the RH and LH rack ends.
16. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner to hold the steering rack steady, and us-
ing SST, torque the rack end.
SST 09922−10010
Torque: 61 N·m (618 kgf·cm, 45 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact to the rack.
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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.
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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)
Page 1779 of 2062
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Return Tube
Intermediate Shaft Assembly
Pressure Feed Tube
PS Gear Assembly
Pitman Arm Sub−Assembly
With Relay Rod
Spring Washer 44 (450, 33)
*36 (365, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
35 (360, 26)
44 (450, 33)
*36 (365, 26)
142 (1450, 105)
177 (1800, 130)
SR080−01
SR−72
− STEERINGPOWER STEERING GEAR (4WD)
1746 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING GEAR (4WD)
COMPONENTS
Page 1780 of 2062
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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)
Page 1787 of 2062
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R15586
R15587
SST
R12202
Hexagon
Wrench SR−80
− STEERINGPOWER STEERING GEAR (4WD)
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−72)
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) Install the valve body assembly into the gear housing.
NOTICE:
Ensure that the power piston nut does not come off
the worm shaft.
Be careful not to damage the teflon ring.
(c) Torque the 4 bolts.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(d) 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 and install it
to the plunger guide nut.
(b) Install the plunger guide nut with a hexagon wrench (10
mm).
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
