Page 746 of 969
F41497
SST
F41498
SST
F40050
Matchmarks
ZK8184
51-24
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2599 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the steering left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering left turn pressure
tube.
18. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the steering right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering right turn pres-
sure tube.
19. FIX RACK & PINION POWER STEERING GEAR ASSY
(a) Using SST, secure the rack & pinion power steering gear
assy.
SST 09612-00012
HINT:
Tape the SST before use.
20. REMOVE TIE ROD ASSY LH
(a) Place matchmarks on the tie rod assy LH and steering
rack end sub-assy.
(b) Loosen the lock nut, and remove the tie rod assy LH and
lock nut.
21. REMOVE TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
22. INSPECT TIE ROD ASSY LH
(a) Secure the tie rod assy LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate
of 2 - 4 seconds per 1 turn and take the torque reading
of the 5th turn.
Turning torque:
0.83 - 3.43 NVm (8.5 - 35.0 kgfVcm, 7.3 - 30.4 in.Vlbf)
23. INSPECT TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
Page 754 of 969
C03629
R11573
SST
Valve Ring
F41508
Vinyl Tape
F41509
SST
F41512
51-32
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2607 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
46. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the control valve ring.
(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and
settle them down with your fingers.
(d) Carefully slide the tapered end of SST over the control
valve rings until they fit to the control valve.
SST 09631-20081
NOTICE:
Be careful not to damage the control valve rings.
(e) To prevent power steering control valve upper oil seal lip
damage, wind vinyl tape around the serrated part of the
control valve.
(f) Coat the power steering control valve upper oil seal lip
with power steering fluid.
(g) Install the control valve to the control valve housing.
NOTICE:
Be careful not to damage the control valve ring and power
steering control valve upper oil seal lip.
(h) Coat a new oil seal lip with power steering fluid.
(i) Using SST and a press, install the oil seal.
SST 09612-2201 1
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
(j) Apply grease to the needle bearing.
(k) Install a new gasket to the control valve housing.
(l) Wind vinyl tape around the serration part of the control
valve.
(m) Install the control valve housing to the rack housing with
the 2 bolts.
Torque: 21 NVm (214 kgfVcm, 15 ftVlbf)
Page 755 of 969
F41513
SST
F41502
F41608
F41514SST
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-33
2608 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(n) Using SST, stop the control valve rotation and install a
new lock nut.
Torque: 24.5 NVm (250 kgfVcm, 18 ftVlbf)
SST 09616-0001 1
(o) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(p) Using a socket wrench (27 mm), install the rack housing
cap.
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
(q) Using a punch and a hammer, stake the rack housing cap
and rack housing.
47. INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the rack guide.
(b) Install the rack guide.
(c) Install the compression spring.
(d) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH steering rack
ends sub-assy.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
Page 756 of 969
F41515SST
F41516
SST
F41517
SST
SST
Rack Guide
Spring Cap
F41518SSTFulcrum Length Rack Guide Spring
Cap Nut
SST
51-34
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2609 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Using SST, loosen the rack guide spring cap.
SST 09631-10021
(d) Using SST, turn the control valve to the right and left 1 or
2 times.
SST 09616-0001 1
(e) Using SST, loosen the rack guide spring cap until the
compression spring is not functioning.
SST 09631-10021
(f) Using SST and a torque wrench, tighten the rack guide
spring cap until the preload is within specification.
SST 09616-0001 1, 09631-10021
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(g) Apply sealant to 2 or 3 threads of the rack guide spring
cap nut.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(h) Temporarily install the rack guide spring cap nut.
(i) Using SST, hold the rack guide spring cap and using
another SST, tighten the rack guide spring cap nut.
SST 09616-0001 1, 09922-10010
Torque: 48 NVm (489 kgfVcm, 35 ftVlbf)
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.).
(j) Precheck the total preload.
Preload (turning):
1.2 - 1.5 NVm (12.2 - 15.3 kgfVcm, 10.6 - 13.3 in.Vlbf)
(k) Remove the RH and LH steering rack ends sub-assy.
Page 757 of 969
F40555
MP Grease
F40538F43004
Vinyl Tape
F41576
SST
SST Fulcrum
Length
C35928
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-35
2610 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(l) Apply MP grease into the control valve, as shown in the
illustration.
(m) Wind vinyl tape around the serration part of the control
valve.
(n) Install the dust cover to the control valve housing.
49. INSTALL STEERING RACK END SUB-ASSY
(a) Install a new 2 claw washers, and temporarily install the
2 steering rack ends sub-assy.
HINT:
Align the claws of the claw washer with the power steering rack
grooves.
(b) Using 2 SSTs, install the 2 steering rack ends sub-assy.
SST 09922-10010
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Using SST, hold the power steering rack and install the
steering rack end sub-assy.
Use a torque wrench with a fulcrum length of 345 mm
(13.58 in.).
(c) Using a brass bar and a hammer, stake the claw washer.
NOTICE:
Avoid any impact to the power steering rack.
Page 758 of 969
ZX9390F41951
F40556
SST
51-36
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2611 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
50. INSPECT STEERING RACK END SUB-ASSY
(a) Ensure that the steering rack end sub-assy hole is not
clogged with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and steering wheel is turned.
51. INSTALL STEERING RACK BOOT NO.2
(a) Install the steering rack boot No.2.
52. INSTALL STEERING RACK BOOT NO.1
HINT:
Remove the steering rack boot No.1 by the same procedures with steering rack boot No.2.
53. INSTALL STEERING RACK BOOT NO.2 CLAMP
(a) Using SST, tighten the steering rack boot No.2 clamp, as
shown in the illustration.
SST 09521-24010
Clearance: 3.0 mm (0.118 in.) or less
NOTICE:
Be careful not to damage the steering rack boot No.2.
54. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST 09521-24010
NOTICE:
Be careful not to damage the steering rack boot No.1.
HINT:
Install the steering rack boot No.1 clamp by the same proce-
dures with steering rack boot No.2 clamp.
55. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 steering rack boot clips.
56. INSTALL TIE ROD ASSY LH
(a) Screw the lock nut and tie rod assy LH onto the steering rack end sub-assy until the matchmarks are
aligned.
HINT:
After adjusting toe-in, torque the lock nut.
57. INSTALL TIE ROD ASSY RH
HINT:
Install the RH side by the same procedures with LH side.
Page 759 of 969
F41519
Fulcrum
Length
SST
F41613
Fulcrum
Length
SST
F41496
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-37
2612 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
58. INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install
them to the steering left turn pressure tube.
(b) Using SST, install the steering left turn pressure tube to
the rack & pinion power steering gear assy.
SST 09023-38201
Torque: 11.5 NVm (117 kgfVcm, 8 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 345 mm
(9.84 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
59. INSTALL STEERING RIGHT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install
them to the steering right turn pressure tube.
(b) Using SST, install the steering right turn pressure tube to
the rack & pinion power steering gear assy.
SST 09023-38201
Torque: 11.5 NVm (117 kgfVcm, 8 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 345 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
60. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Install the power steering rack housing heat insulator.
HINT:
Install nut when installing the return clamp.
61. INSTALL RACK & PINION POWER STEERING GEAR
ASSY
(a) Install the rack & pinion power steering gear assy with the
2 bolts and 2 nuts.
Torque: 70 NVm (714 kgfVcm, 52 ftVlbf)
Page 760 of 969
F41568
F41587
Fulcrum
Length
SST
F41586
Fulcrum
Length
SST
F41602
51-38
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2613 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Connect the tube clamp with the bolt.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
62. CONNECT PRESSURE FEED TUBE ASSY
(a) Using SST, connect the pressure feed tube assy to the
rack & pinion power steering gear assy.
SST 09023-12701
Torque: 22.5 NVm (229 kgfVcm, 17 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
(b) Using SST, connect the return tube assy to the rack & pin-
ion power steering gear assy.
SST 09023-12701
Torque: 22.5 NVm (229 kgfVcm, 17 ftVlbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in the case that SST is paral-
lel to a torque wrench.
(c) Install the return tube assy clamp with the nut.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)