1996 TOYOTA TERCEL Gear oil

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.

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.

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.

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.