2001 TOYOTA AVALON Service Repair Manual

R11645
SST
R11646
SSTRack Guide
Spring Cap Lock Nut
R11647
SST Rack Guide
Spring Cap
R11648
SST SR-42
- STEERINGPOWER STEERING GEAR
1505 Author
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2001 AVALON (RM808U)
(b) Using a spanner (24 mm) hold the steering rack steadily
and using SST, remove the rack end.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
(c) Remove the claw washer.
(d) Employ the same manner described above to the other
side.
HINT:
Mark the RH and LH rack ends.
6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING, RACK GUIDE SUB-ASSEMBLY
(a) Using SST, remove the rack guide spring cap.
SST 09631-10021
(b) Remove the rack guide spring and rack guide sub-as-
sembly.
8. REMOVE RACK HOUSING CAP
9. REMOVE SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and remove the
self-locking nut.
SST 09616-0001 1
10. REMOVE DUST SEAL

R11553
Matchmarks
R11554
Vinyl TapePress
Shop Rag
R11649
Matchmarks
R11650
R11651
SSTWire
Cylinder End
Stopper
- STEERINGPOWER STEERING GEAR
SR-43
1506 Author
: Date
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2001 AVALON (RM808U)
11. REMOVE CONTROL VALVE HOUSING WITH CON-
TROL VALVE ASSEMBLY
(a) Place matchmarks on the control valve housing and rack
housing.
(b) Remove the 2 bolts and control valve housing.
(c) Remove the gasket from the rack housing.
12. REMOVE CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the control valve shaft.
(b) Press out the control valve assembly with the oil seal.
NOTICE:

Place a shop rag between the valve housing and the
blocks.

Be careful not to drop the valve assembly.

Be careful not to damage the oil seal lip.
13. REMOVE OIL SEAL
Remove the oil seal from the control valve assembly.
14. REMOVE RACK HOUSING NO. 2 BRACKET AND
RACK HOUSING NO. 2 GROMMET
(a) Place matchmarks on the rack housing No. 2 bracket and
rack housing.
(b) Using a screwdriver, pry the clamp of the rack housing No.
2 bracket and remove the rack housing No. 2 bracket.
(c) Remove the rack housing No. 2 grommet from the rack
housing No. 2 bracket.
15. REMOVE CYLINDER END STOPPER
(a) Using SST, turn the cylinder end stopper clockwise until
the wire end is visible through the service hole.
SST 09631-10021
(b) Using SST, turn the cylinder end stopper counterclock-
wise, and remove the wire and cylinder end stopper.
SST 09631-10021

R11555
Brass Bar
Bushing
F01791
SST
Oil Seal
SR-44
- STEERINGPOWER STEERING GEAR
1507 Author
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2001 AVALON (RM808U)
16. REMOVE STEERING RACK AND BUSHING
(a) Using a brass bar and hammer, tap out the steering rack
with the bushing.
(b) Remove the bushing from the steering rack.
(c) Remove the O-ring from the bushing.
17. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00290),
09950-70010 (09951-07360)

R10072
Dial Indicator
SR0RV-02
- STEERINGPOWER STEERING GEAR
SR-45
1508 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
INSPECT STEERING RACK
(a) Using a dial indicator, check the steering rack for runout
and for teeth wear and damage.
Maximum runout: 0.3 mm (0.012 in.)
(b) Check the back surface for wear and damage.

SR0EY-06
F13589
SST
Fulcrum Length
SR-56
- STEERINGPOWER STEERING GEAR
1519 Author
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2001 AVALON (RM808U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
(a) Install the PS gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
(b) Install the 2 gear assembly set bolts and nuts.
Torque: 181 N´m (1,850 kgf´cm, 134 ft´lbf)
HINT:
Lift up the stabilizer bar and install the bolts.
2. INSTALL NO. 1 FUEL TUBE PROTECTOR
Install the No. 1 fuel tube protector with 2 bolts and nut.
3. CONNECT STABILIZER BAR
Connect the stabilizer bar with the 4 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
4. CONNECT PRESSURE FEED AND RETURN TUBES
(a) Coat 2 new O-rings with power steering fluid and install
them to the pressure feed and return tubes.
(b) Using SST, connect the pressure feed and return tubes.
SST 09023-38400
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.
5. CONNECT CLAMP PLATE
Connect the clamp plate with nut.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
6. CONNECT INTERMEDIATE SHAFT SUB-ASSEMBLY
(See page SR-22)
7. CONNECT RH AND LH TIE ROD ENDS
(See page SA-13)
8. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
9. CENTER SPIRAL CABLE (See page SR-22)
10. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and steering
column main shaft.
(b) Temporarily tighten the steering wheel set nut.
(c) Connect the connector.
11. BLEED POWER STEERING SYSTEM
(See page SR-4)

- STEERINGPOWER STEERING GEAR
SR-57
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2001 AVALON (RM808U)
12. CHECK STEERING WHEEL CENTER POINT
13. TORQUE STEERING WHEEL SET NUT
Torque: 50 N´m (510 kgf´cm, 37 ft´lbf)
14. INSTALL STEERING WHEEL PAD (See page SR-22)
15. CHECK FRONT WHEEL ALIGNMENT
(See page SA-4)
16. w/ VSC:
PERFORM STEERING ANGLE SENSOR ZERO POINT
CALIBRATION (See page DI-252)

W03561
Press
SST
Oil Seal SST
SR0RW-03
W02101
SST
Rack Teeth End
R11574
Vinyl TapeBushing
- STEERINGPOWER STEERING GEAR
SR-49
1512 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID OR MOLYBDENUM DISULFIDE
LITHIUM BASE GREASE (See page SR-37)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950- 60010 (09951- 00240, 09951- 00430,
09952-06010), 09950-70010 (09951-07360)
NOTICE:

Make sure that the oil seal is installed facing in 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 steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the steering rack teeth end
and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the steering rack into the rack housing.
NOTICE:
Be careful not to damage the oil seal lip.
(d) Remove SST.
SST 09631-33010
4. INSTALL BUSHING
(a) Coat a new O-ring with power steering fluid and install it
to the bushing.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the bushing.
NOTICE:

Make sure that the bushing is installed facing in the
correct direction.

Be careful not to damage the oil seal lip.

R11656
Cylinder
End StopperWire SST
R00662
SST
R11657
R11658
R11575
Vinyl Tape SR-50
- STEERINGPOWER STEERING GEAR
1513 Author
: Date
:
2001 AVALON (RM808U)
5. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end
stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using SST, turn the cylinder end stopper clockwise 450
± 50°.
SST 09631-10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
(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 RACK HOUSING NO. 2 BRACKET AND
RACK HOSING NO. 2 GROMMET
(a) Install the rack housing No. 2 grommet to the rack housing
No. 2 bracket.
HINT:
Align the projection of the rack housing No. 2 grommet with the
hole of the rack housing No. 2 bracket.
(b) Align the matchmarks on the rack housing No. 2 bracket
and rack housing.
(c) Place the rack housing No. 2 bracket in a vise and install
the vise to fasten the clamp.
8. INSTALL CONTROL VALVE ASSEMBLY
(a) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the control valve shaft.
(b) Coat the teflon rings with power steering fluid.
(c) Install the control valve assembly into the control valve
housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.