Page 955 of 1202
SR1F1-01
R14429
W02101
SST
Rack Teeth End SR-56
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR
MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
(See page SR-46)
2. INSTALL OIL SEAL AND SPACER
(a) Coat a new oil seal lip with power steering fluid.
(b) Install the oil seal and spacer to SST, and drive in them
with a plastic hammer.
SST 09950-60010 (09951-00220, 09951-00380,
09952-06010), 09951-70010 (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
(a) Install SST to the rack.
SST 09631-10041
HINT:
If necessary, scrape the burrs off the rack teeth end and bur-
nish.
(b) Coat SST with power steering fluid.
(c) Insert the rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal.
(d) Remove the SST.
Page 956 of 1202

Z03128
Vinyl Tape
R11057
SST
SR4264
SST
- STEERINGPOWER STEERING GEAR
SR-57
1996 TERCEL (RM440U)
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. INSTALL BUSHING AND CYLINDER END STOPPER
(a) Install a new bushing to the stopper.
(b) Using SST, torque the stopper.
SST 09631-20090
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the stopper and rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
NOTICE:
Do not install union seats.
(b) Apply 53 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) Push the valve assembly into the rack housing.
Page 957 of 1202

Z13779
SST
Bearing
W04072
SST
Bearing Press
Oil Seal
SR4281
SST
Z13781
Punch SR-58
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
8. INSTALL BEARING
Using SST, press in a new bearing.
SST 09612-2201 1
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal until it contacts the bear-
ing.
SST 09612-2201 1
NOTICE:
Make sure to install the oil seal facing the correct direction.
(c) Using snap ring pliers, install a new snap ring to the rack
housing.
10. INSTALL SELF-LOCKING NUT
(a) Coat a new bearing with molybdenum disulfide lithium
base grease and install it to the control valve shaft.
(b) Using SST, stop the control valve shaft rotating and
torque a new nut.
SST 09616-00010
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
11. 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) Torque the cap.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the cap at 2 places.
12. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING, AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Install the guide to the rack housing.
(c) Apply sealant to 2 or 3 threads of the spring cap.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(d) Temporarily install the cap.
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