1996 TOYOTA TERCEL Service Repair Manual

SR0KX-04
SR-46
- STEERINGPOWER STEERING GEAR
966 Author
: Date
:
1996 TERCEL (RM440U)
POWER STEERING GEAR
COMPONENTS

- STEERINGPOWER STEERING GEAR
SR-47
967 Author
: Date
:
1996 TERCEL (RM440U)

Union Seat SR-48
- STEERINGPOWER STEERING GEAR
968 Author
: Date
:
1996 TERCEL (RM440U)

SR0KY-02
R11074
SST
SR4244
- STEERINGPOWER STEERING GEAR
SR-49
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. w/ Airbag:
REMOVE STEERING WHEEL PAD (See page SR-13)
3. w/ Airbag:
REMOVE STEERING WHEEL (See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 2 bolts and nut.
6. DISCONNECT SLIDING YOKE (See page SR-13)
7. REMOVE OXYGEN SENSOR
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, compression springs and gasket.
(b) Remove the bolt, clamp and gasket.
(c) Disconnect the 2 rings.
9. REMOVE ENGINE REAR MOUNT INSULATOR
Remove the 6 bolts.
10. REMOVE ENGINE REAR MOUNT BRACKET
Remove the 2 bolts.
11. DISCONNECT 2 VACUUM HOSES
12. M/T:
DISCONNECT CONTROL CABLES
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
(c) Disconnect the 2 cables from the control lever housing
support bracket.
13. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631-22020
14. DISCONNECT TUBE CLAMP
Remove the bolt.
15. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
16. REMOVE PS GEAR ASSEMBLY
(a) Slide the gear assembly to the RH side of the vehicle.
(b) Slide the gear assembly to the LH side and pull it out.

SR17W-02
R11026
SST
R11027
SST
R13122
R11029
SST SR-50
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES
(a) Using SST, remove the tube.
SST 09633-00020
(b) Remove the 2 union seats from the rack housing.
3. REMOVE AIR CONTROL VALVE
4. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS (See page SR-37)
5. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
6. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS (See page SR-37)
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
8. REMOVE RACK GUIDE SPRING CAP
Using a hexagon wrench (21 mm), remove the cap.
9. REMOVE RACK GUIDE SPRING, RACK GUIDE AND
RACK GUIDE SEAT
Remove the seat from the guide.
10. REMOVE RACK HOUSING CAP

SR4297
SST
R06217
SST
Pin
Pin
R11075
SST
R11056
SST
- STEERINGPOWER STEERING GEAR
SR-51
1996 TERCEL (RM440U)
11. REMOVE SELF-LOCKING NUT
Using SST, stop the control valve rotating and remove the nut.
SST 09616-00010
12. REMOVE CONTROL VALVE ASSEMBLY WITH OIL
SEAL AND BEARING
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, remove the valve assembly with the oil seal
and bearing.
SST 09613-12010
NOTICE:
Never attempt to tap out the control valve as this would
damage it.
(c) Remove the oil seal from the valve assembly.
(d) Using SST, remove the bearing from the valve assembly.
SST 09950-40010 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04050,
09957-04010, 09958-04010)
13. REMOVE BEARING
Using a brass bar and hammer, tap out the bearing from the
rack housing.
14. REMOVE CYLINDER END STOPPER AND BUSHING
Using SST, remove the stopper and bushing.
SST 09631-20090

SR4282
SST
SR-52
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. REMOVE STEERING RACK WITH OIL SEAL
(a) Using SST, press out the rack with the oil seal.
SST 09612-24014 (09612-10061)
NOTICE:
Take care not to drop the rack.
(b) Remove the oil seal from the rack.
16. REMOVE SPACER AND OIL SEAL
Using SST and a hammer, drive out the spacer and oil seal.
SST 09950-60010 (09951-00220),
09950-70010 (09951-07360)
NOTICE:
Do not damage the rack housing.

SR0L0-02
R10072
Dial Indicator
R11358
Cylinder Gauge
Micrometer
Bushing
R11357
BushingSST Steel
Plate
R11359
Brass Bar
Oil Seal
- STEERINGPOWER STEERING GEAR
SR-53
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
Using a dial indicator, check the rack for runout and teeth wear
and damage.
Maximum runout: 0.30 mm (0.0118 in.)
2. MEASURE OIL CLEARANCE BETWEEN CONTROL
VALVE ASSEMBLY AND BUSHING
Using a micrometer and a cylinder gauge, measure the oil clear-
ance.
Standard clearance:
0.050 - 0.083 mm (0.00197 - 0.00327 in.)
Maximum clearance: 0.125 mm (0.00492 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST and 2 steel plates, remove the bushing from
the rack housing.
SST 09612-65014 (09612-01030)
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 rack housing.
(b) Using a brass bar and a hammer, remove the oil seal from
the rack housing.
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and ham-
mer, press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.