1996 TOYOTA TERCEL lock

R12036
SST
R15598
SSTVinyl Tape
R13864
Cutout Portion SR-38
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
7. REMOVE PINION BEARING ADJUSTING SCREW
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 PINION BEARING ADJUSTING SCREW
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the steering pinion.
(b) Using SST, remove the screw.
SST 09612-24014 (09616-10020)
9. REMOVE STEERING PINION WITH BEARING
Fully pull the steering rack from the steering pinion side of the
rack housing and align the rack cutout portion with the pinion.
NOTICE:
Be careful not to damage the serrations.
10. REMOVE STEERING RACK
NOTICE:
To avoid damaging the bushing, remove the rack from the
steering pinion housing side of the rack housing without
revolving it.

R12038
SSTFulcrum Length SR-42
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
(b) Using SST and a torque wrench, loosen the screw until
the preload is within specification.
SST 09612-24014 (09616-10010, 09616-10020)
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
6. INSTALL PINION BEARING ADJUSTING SCREW
LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, stop the pinion bearing adjusting screw rotat-
ing and using another SST, torque the nut.
SST 09612-24014 (09616-10020), 09922-10010
Torque: 85 N´m (871 kgf´cm, 63 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 380 mm (14.96
in.).
(c) Recheck the pinion preload.
Preload (turning):
0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.´lbf)
7. INSTALL RACK GUIDE, RACK GUIDE SPRING AND
RACK GUIDE SPRING 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) Temporarily install the cap.

R12818Hexagon Wrench12°
R15481
SST
Z14313
Hexagon WrenchSST
R15482
Hexagon
Wrench SST
Fulcrum
Length
- STEERINGMANUAL STEERING GEAR
SR-43
1996 TERCEL (RM440U)
8. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (19 mm), torque the rack guide
spring cap.
Torque: 14.7 N´m (150 kgf´cm, 10.8 ft´lbf)
(c) Using a hexagon wrench (19 mm), return the cap 12°.
(d) Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
(e) Using a hexagon wrench (19 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (19
mm), tighten the cap until the preload is within specifica-
tion.
SST 09612-24014 (09616-10010)
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (19 mm), hold the rack guide
spring cap rotating and using SST, torque the nut.
SST 09922-10010
Torque: 41 N´m (419 kgf´cm, 30 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) Recheck the total preload.
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
(d) Remove the RH and LH rack ends.

R12040
SST
Fulcrum
Length
N00349
R15520
0 mm
6 mm
(0.24 in.)
R15519
SR-44
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
10. 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, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 43 N´m (434 kgf´cm, 31 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 on the rack.
11. INSTALL RH AND LH BOOTS, CLAMPS AND CLIPS
(a) Install the rack boot.
NOTICE:
Be careful not to damage or twist the boot.
(b) Install the clamp screw, as shown in the illustration.
(c) Install the clip.
HINT:
Face the open ends of the clips outward/upward as shown in
the illustration, to avoid damage to the boot.
12. 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 nut.
(See page SA-4)
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)

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

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.

W04432
Hexagon
Wrench
12°
W00840
SST
W00841
SST
Hexagon
Wrench
W01203SSTHexagon
Wrench Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-59
1996 TERCEL (RM440U)
13. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616-00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (21
mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616-00010
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
14. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (21 mm), hold the rack guide
spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 36 N´m (366 kgf´cm, 26 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 300 mm (11.81
in.).
(c) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
(d) Remove the RH and LH rack end.